Thermoplastic resin composition, method for producing same, and molded body

ABSTRACT

The purpose of the present invention is to provide: a thermoplastic resin composition which exhibits excellent rigidity, while having excellent impact strength characteristics; and a method for producing the thermoplastic resin composition. This thermoplastic resin composition, wherein a polyolefin resin contains a polyamide resin that is dispersed therein, is characterized in that: the thermoplastic resin composition is obtained by melting and kneading a polyolefin resin and a mixed resin that is obtained by melting and kneading a polyamide resin and a compatibilizer; and the compatibilizer is a modified elastomer that is obtained by providing an elastomer (such as an olefin-based thermoplastic elastomer or a styrene-based thermoplastic elastomer) with a reactive group that is reactive with the polyamide resin. The present invention also relates to a thermoplastic resin composition which is obtained by melting and kneading from 1% by mass to 80% by mass (inclusive) of a plant-derived polyamide resin such as polyamide 11, from 5% by mass to 75% by mass (inclusive) of a polyolefin resin and from 1% by mass to 30% by mass (inclusive) of a compatibilizer that is an olefin-based thermoplastic elastomer that is modified with an acid.

The present application is a Continuation Application of U.S.application Ser. No. 14/366,894, filed Jun. 19, 2014, which is aNational Stage of International Patent Application No. PCT/JP2012/083368filed Dec. 21, 2012, which claims priority to Japanese Application No.2012-280270 filed Dec. 21, 2012, Japanese Application No. 2012-280269filed Dec. 21, 2012, Japanese Application No 2011-282232 filed Dec. 22,2011 and Japanese Application No. 2011-282233 filed Dec. 22, 2011. Thedisclosures of U.S. application Ser. No. 14/366,894 and InternationalPatent Application No. PCT/JP2012/083368 are incorporated by referenceherein in their entireties.

FIELD OF THE INVENTION

The present invention relates to a thermoplastic resin composition and aproduction method thereof, and a molded article. More specifically, theinvention relates to a thermoplastic resin composition that is excellentin impact strength as well as rigidity, and to a production methodthereof. The present invention also relates to a plant-derived polyamideresin containing thermoplastic resin composition that is excellent inimpact strength as well as rigidity, and to a molded article.

BACKGROUND ART

A polymer blend (including a polymer alloy) that is produced by mixingresins which differ in polarity to modify the properties of the resinsis extensively studied (see Patent Literatures 1 and 2, for example).

When the compatibility of the resins is insufficient, a deterioration inmechanical properties (e.g., impact strength) may occur, and themodification effects due to the polymer blend may not be obtained.Therefore, it is necessary to improve the compatibility of the resinsusing some kind of method. For example, in the case of producing apolymer alloy of a polypropylene resin and a polyamide resin, a methodthat utilizes a compatibilizer (e.g., anhydrous maleic acid-modifiedpolypropylene) is proposed to improve compatibility.

Interior automotive components and exterior automotive componentsrequire high mechanical properties, and indispensably need compatibilitybetween impact strength and rigidity (flexural modulus).

However, in the above-described polymer blends, impact strength andrigidity are in a trade-off relation. In particular, since they are in areciprocal relation in which when impact strength is emphasized,rigidity becomes insufficient, a polymer blend that exhibits bothsufficient impact strength and sufficient rigidity has not been obtainedyet.

Conventionally, polylactic acid (PLA), polybutylene succinate (PBS),polytrimethylene terephthalate (PTT), polyamide 11 (PA11), and the likeare known as a plant-derived resin used for a plant-derived plasticmaterial. An alloyed plant-derived plastic material is known that isproduced by blending a petroleum-derived resin (e.g., polyolefin resinor ABS) with a plant-derived resin. For example, Patent Literatures 3and 4 describe an example of an alloyed plant-derived plastic materialthat utilizes PLA. Patent Literatures 5 and 6 describe an example of analloyed plant-derived plastic material that utilizes PBS. Further,Patent Literature 7 describes an example of an alloyed plant-derivedplastic material that utilizes PAH.

However, a plant-derived plastic material that utilizes PLA, PBS, or PTThas a problem in that the properties of the plant-derived resin mayremain unchanged (in particular, sufficient mechanical properties maynot be obtained). For example, impact strength, heat resistance, andhydrolyzability may not be sufficiently achieved when using PLA,rigidity, heat resistance, and hydrolyzability may not be sufficientlyachieved when using PBS, and impact strength and hydrolyzability may notbe sufficiently achieved when using PTT. Therefore, use of aplant-derived resin (plant-derived plastic material) is limited (e.g.,it is difficult to apply a plant-derived resin (plant-derived plasticmaterial) as an automotive interior material to parts (e.g., door trimor deck side trim) for which particularly high mechanical properties arerequired). In the case of using a plant-derived resin as a basematerial, it is necessary to modify the resin, and an increase in costmay occur. A thermoplastic resin composition that utilizes PA11,disclosed in Patent Literature 5 has a problem in that an ABS resin(inexpensive general-purpose plastic) that is used in combination withPA11 is expensive as compared with an olefin-based resin (e.g.,polypropylene), and has insufficient solvent resistance since it is anamorphous resin.

High mechanical properties are required in automobile field includinginterior parts and exterior parts, and it is indispensable to achieveimpact strength and rigidity (flexural modulus) in combination.

However, in the above-described polymer blends, impact strength andrigidity are in a trade-off relation. In particular, since they are in areciprocal relation in which when impact strength is emphasized,rigidity becomes insufficient, both of impact strength and rigidity havenot been fully satisfied so far.

PRIOR ART LITERATURE Patent Literature

Patent Literature 1: JP A 2007-297441

Patent Literature 2: JP A 2009-203410

Patent Literature 3: JP A 2009-126916

Patent Literature 4: JP A 2010-265444

Patent Literature 5: JP A 2010-18694

Patent Literature 6: JP A 2009-209227

Patent Literature 7: JP A 2008-214585

SUMMARY OF THE INVENTION Problems that the Invention is to Solve

The invention was conceived in view of the above situation. An object ofthe present invention is to provide a thermoplastic resin compositionthat is excellent in impact strength as well as rigidity, and aproduction method thereof.

The invention was conceived in view of the above situation. An object ofthe present invention is to provide a thermoplastic resin compositionutilizing a plant-derivative polyamide resin that is excellent inrigidity as well as impact strength, and a molded article.

Means for Solving Problems

The invention as described in claim 1 in order to solve the aboveproblems is a thermoplastic resin composition in which a polyamide resinis dispersed in a polyolefin resin and is characterized in that thethermoplastic resin composition is obtained by molten blending thepolyolefin resin, and a mixed resin which is obtained by molten blendingthe polyamide resin and a compatibilizer, and that the compatibilizer isa modified elastomer in which a reactive group which reacts with thepolyamide resin is substituted to an elastomer.

The invention as described in claim 2 is a thermoplastic resincomposition in which the elastomer is a styrene-based thermoplasticelastomer, or an olefin-based thermoplastic elastomer consisting of apolymer of an α-olefin having carbon atoms of 3 to 8 and ethylene orpropylene in the description of claim 1.

The invention as described in claim 3 is a thermoplastic resincomposition in which the polyamide resin is at least one resin selectedfrom a group consisting of polyamide 11, polyamide 6, polyamide 66,polyamide 610, polyamide 612, polyamide 614, polyamide 12, polyamide 6T,polyamide 6I, polyamide 9T, polyamide MST, polyamide 1010, polyamide1012, polyamide 10T, polyamide MXD6, polyamide 6T/66, polyamide 6T/6I,polyamide 6T/6I/66, polyamide 6T/2M-5T, and polyamide 9T/2M-8T in thedescription of claim 1 or 2.

The invention as described in claim 4 is a production method of athermoplastic resin composition in which a polyamide resin is dispersedin a polyolefin resin, and is characterized in that the method has amixing process in which an olefin resin and a mixed resin obtained bymolten blending a polyamide resin and a compatibilizer are subjected tomolten blending, and that the compatibilizer is a modified elastomer inwhich a reactive group which reacts with the polyamide resin issubstituted to an elastomer.

Additionally, the invention as described in claim 5 in order to solvethe above problems is a plant-derived polyamide resin containingthermoplastic resin composition, and is characterized in that thethermoplastic resin composition is obtained by molten blending thepolyamide resin, a polyolefin resin, and a compatibilizer, that thepolyamide resin is at least one plant-derived polyamide resin selectedfrom a group consisting of polyamide 11, polyamide 610, polyamide 614,polyamide 1010, and polyamide 10T, that a content of the polyamide resinis in a range from 1% to 80% by mass based on 100% by mass of a total ofthe polyamide resin, the polyolefin resin, and the compatibilizer, thata content of the polyolefin resin is in a range from 5% to 75% by massbased on 100% by mass of a total of the polyamide resin, the polyolefinresin, and the compatibilizer, that the compatibilizer is anacid-modified olefin-based thermoplastic elastomer, and that a contentof the compatibilizer is in a range from 1% to 30% by mass based on 100%by mass of a total of the polyamide resin, the polyolefin resin, and thecompatibilizer.

The invention as described in claim 6 is a plant-derived polyamide resincontaining thermoplastic resin composition in which the content of thepolyamide resin is in a range from 10% to 40% by mass, the content ofthe polyolefin resin is in a range from 50% to 75% by mass, and thecontent of the compatibilizer is in a range from 5% to 30% by mass inthe description of claim 5.

The invention as described in claim 7 is a plant-derived polyamide resincontaining thermoplastic resin composition in which the compatibilizeris a maleic anhydride modified ethylene 1-butene copolymer or ananhydrous maleic acid-modified ethylene octene copolymer in thedescription of claim 5 or 6.

The invention as described in claim 8 is a plant-derived polyamide resincontaining thermoplastic resin composition in which the polyamide resinis at least one selected from the group consisting of polyamide 11,polyamide 610, polyamide 1010, and polyamide 10T, and the polyolefinresin is a polypropylene in the description of claim 7.

The invention as described in claim 9 is a plant-derived polyamide resincontaining thermoplastic resin composition in which a specific gravityis in a range from 0.89 to 1.05 in the description of claim 8.

The invention as described in claim 10 is a molded article and ischaracterized by comprising the plant-derived polyamide resin containingthermoplastic resin composition described in any one of claims 5 to 9.

Effect of the Invention

Since the thermoplastic resin composition of the present invention isobtained by molten blending a polyolefin resin and a mixed resinobtained by molten blending a polyamide resin and a specificcompatibilizer, the thermoplastic resin composition is excellent inimpact strength as well as rigidity.

In the case where the elastomer is an olefin-based thermoplasticelastomer which is a polymer of ethylene or propylene, and an α-olefinhaving 3 to 8 carbon atoms, or a styrene-based thermoplastic elastomer,more excellent impact strength and rigidity can be obtained.

In the case where the polyamide resin is a specific resin, it ispossible to obtain a material that exhibits both excellent impactstrength and excellent rigidity.

Since the production method of a thermoplastic resin composition in thepresent invention has the mixing process that melt-mixes a polyolefinresin and a mixed resin obtained by molten blending a polyamide resinand a specific compatibilizer, it is possible to easily obtain athermoplastic resin composition that is excellent in impact strength aswell as rigidity.

According to the plant-derived polyamide resin containing thermoplasticresin composition in another present invention, a molded article thatutilizes a plant-derived polyamide resin and is excellent in impactstrength as well as rigidity can be obtained.

When a content of the polyamide resin is in a range from 10% to 40% bymass, a content of the polyolefin resin is in a range from 50% to 75% bymass, and a content of the compatibilizer is in a range from 5% to 30%by mass, it is possible to obtain a plant-derived polyamide resincontaining thermoplastic resin composition and has a reduced specificgravity due to a reduction in the content of the polyamide resin, and isexcellent in impact strength as well as rigidity.

When the compatibilizer is an anhydrous maleic acid-modified ethylene1-butene copolymer or an anhydrous maleic acid-modified ethylene octenecopolymer, particularly excellent impact strength and rigidity can beobtained.

When the polyamide resin is polyamide 11, polyamide 610, polyamide 1010,or polyamide 10T, and the polyolefin resin is polypropylene, it ispossible to obtain a thermoplastic resin composition that has lowspecific gravity, and exhibits particularly excellent injectionmoldability while maintaining the excellent properties of each resin.

When the specific gravity is in a range from 0.89 to 1.05, it ispossible to obtain a molded article that has a reduced weight, andexhibits excellent impact strength and excellent rigidity.

The molded article of the present invention exhibits excellent impactstrength and excellent rigidity while utilizing a plant-derivedpolyamide resin.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph relating to Charpy impact strength.

FIG. 2 is a graph relating to Charpy impact strength.

FIG. 3 is an explanatory view illustrating a resin dispersion stateobserved using an SEM.

DESCRIPTION OF EMBODIMENTS

The particulars shown herein are by way of example and for purposes ofillustrative discussion of the embodiments of the present invention onlyand are presented in the cause of providing what is believed to be themost useful and readily understood description of the principles andconceptual aspects of the present invention. In this regard, no attemptis made to show structural details of the present invention in moredetail than is necessary for the fundamental understanding of thepresent invention, the description is taken with the drawings makingapparent to those skilled in the art how the forms of the presentinvention may be embodied in practice.

1. Thermoplastic Resin Composition (I)

The thermoplastic resin composition of the present invention is athermoplastic resin composition in which a polyamide resin is dispersedin a polyolefin resin and is characterized in that the thermoplasticresin composition is obtained by molten blending the polyolefin resin,and a mixed resin which is obtained by molten blending the polyamideresin and a compatibilizer, and that the compatibilizer is a modifiedelastomer in which a reactive group which reacts with the polyamideresin is substituted to an elastomer.

This thermoplastic resin composition may be hereinafter referred to as“thermoplastic resin composition (I)”.

1-1. Components

The polyamide resin is a polymer having a chain-like skeleton formed bypolymerizing a plurality of monomers through an amide bond (—NH—CO—). Inthe thermoplastic resin composition (I) according to the presentinvention, the polyamide resin is a resin which forms a dispersed phasewith respect to the polyolefin resin (described later).

Examples of a monomer constituting the polyamide resin include an aminoacid such as aminocaproic acid, aminoundecanoic acid, aminododecanoicacid, and p-aminomethylbenzoic acid; a lactam such as ε-caprolactam,undecanelactam, and ω-lauryllactam; and the like. These compounds may beused singly or in combination of two or more types thereof.

The polyamide resin can be prepared by copolymerization of a diamine anda dicarboxylic acid. Examples of the diamine used as the monomer includean aliphatic diamine such as ethylenediamine, 1,3-diaminopropane,1,4-diaminobutane, 1,6-diaminohexane, 1,7-diaminoheptane,1,8-diaminooctane, 1,9-diaminononane, 1,10-diaminodecane,1,11-diaminoundecane, 1,12-diaminododecane, 1,13-diaminotridecane,1,14-diaminotetradecane, 1,15-diaminopentadecane,1,16-diaminohexadecane, 1,17-diaminoheptadecane, 1,18-diaminooctadecane,1,19-diaminononadecane, 1,20-diaminoeicosane,2-methyl-1,5-diaminopentane, and 2-methyl-1,8-diaminooctane; analicyclic diamine such as cyclohexanediamine andbis(4-aminocyclohexyl)methane; an aromatic diamine such as axylylenediamine (e.g., p-phenylenediamine and m-phenylenediamine); andthe like. These compounds may be used singly or in combination of two ormore types thereof.

Examples of the dicarboxylic acid used as the monomer include analiphatic dicarboxylic acid such as oxalic acid, malonic acid, succinicacid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaicacid, sebacic acid, undecanedioic acid, dodecanedioic acid, brasylicacid, tetradecanedioic acid, pentadecanedioic acid, and octadecanedioicacid; an alicyclic dicarboxylic acid such as cyclohexanedicarboxylicacid; an aromatic dicarboxylic acid such as phthalic acid, terephthalicacid, isophthalic acid, and napthalenedicarboxylic acid; and the like.These compounds may be used singly or in combination of two or moretypes thereof.

In the present invention, the polyamide resin is preferably a polyamideresin which includes an amide bond-containing unit having 11 carbonatoms in the main chain. Specifically, it is preferable that thepolyamide resin include a structural unit derived from a monomer having11 carbon atoms. It is particularly preferable that the polyamide resinis a polymer which is produced using 11-aminoundecanoic acid orundecanelactam as a monomer (hereinafter may be referred to as“PA11-based resin”). Since 11-aminoundecanoic acid is a monomer obtainedfrom castor oil, 11-aminoundecanoic acid is desirable from the viewpointof environmental protection (particularly from the viewpoint of carbonneutral).

The content of the structural unit derived from a monomer having 11carbon atoms in the PA1-based resin is preferably 50% or more based onthe total structural units. Specifically, the content of a structuralunit derived from a monomer having less than 11 carbon atoms and/or astructural unit derived from a monomer having 12 or more carbon atoms inthe PA11-based resin may be less than 50% based on the total structuralunits. The PA11-based resin may include only the structural unit derivedfrom a monomer having 11 carbon atoms. Specifically, the PA11-basedresin may be polyamide 11 (PA11).

In the thermoplastic resin composition (I) of the present invention,examples of the preferable polyamide other than the PA11-based resinincludes polyamide 6, polyamide 66, polyamide 610, polyamide 612,polyamide 614, polyamide 12, polyamide 6T, polyamide 6I, polyamide 9T,polyamide M5T, polyamide 1010, polyamide 1012, polyamide 10T, polyamideMXD6, polyamide 6T/66, polyamide 6T/6I, polyamide 6T/6I/66, polyamide6T/2M-5T, polyamide 9T/2M-8T, and the like.

These polyamides may be used singly or in combination of two or moretypes thereof.

In the case of using the PA11-based resin and other polyamide, a contentof the other polyamide may be less than 40% by mass based on 100% bymass of a total of the polyamide resin.

The polyamide resin preferably has a structure in which half or more(50% or more) of the carbon atoms contained in the main chain form achain-like skeleton. Specifically, when the polyamide resin includes anaromatic skeleton, it is preferable that less than half (less than 50%)of the carbon atoms in the main chain form the aromatic skeleton.

In the present invention, the polyamide resin may be at least oneplant-derived polyamide resin among polyamide 11, polyamide 610,polyamide 614, polyamide 1010, and polyamide 10T. In this case, it ispossible to obtain a plant-derived plastic material that is excellent inimpact strength and excellent rigidity.

The weight average molecular weight by gel permeation chromatography(GPC) in terms of polystyrene for the polyamide resin is notparticularly limited. The weight average molecular weight is preferablyin a range from 5,000 to 100,000, more preferably from 7,500 to 50,000,and further preferably from 10,000 to 50,000.

The polyolefin resin in the thermoplastic resin composition (I)according to the present invention is a resin which forms a continuousphase with respect to the polyamide resin.

The polyolefin resin is not particularly limited and various polyolefincan be used. Example thereof includes an ethylene homopolymer, apropylene homopolymer, an ethylene propylene copolymer, an ethyleneα-olefin copolymer, a propylene α-olefin copolymer, and the like.

The α-olefin is an unsaturated hydrocarbon compound having carbon atomsof 3 to 8, and example thereof include propylene, 1-butene, 1-pentene,1-hexene, 1-heptene, 3-methyl-1-butene, 4-methyl-1-pentene, and thelike.

These polyolefin resins may be used singly or in combination of two ormore types thereof. In other words, the polyolefin resin may be amixture consisting of the polymers described above.

The weight average molecular weight by GPC in terms of polystyrene forthe polyolefin resin is not particularly limited. The weight averagemolecular weight is preferably in a range from 10,000 to 500,000, morepreferably from 100,000 to 450,000, and further preferably from 200,000to 400,000.

The polyolefin resin is a polyolefin which does not have an affinitywith the polyamide resin and does not have a reactive group that reactswith the polyamide resin either. Thus, the polyolefin resin is differentfrom a polyolefin-based component as the compatibilizer to be describedbelow.

The compatibilizer is a modified elastomer in which a reactive groupthat reacts with the polyamide resin is substituted to an elastomer.

The elastomer is a thermoplastic elastomer in general. Among thethermoplastic elastomer, an olefin-based thermoplastic elastomer and astyrene-based thermoplastic elastomer are preferable.

Examples of the olefin-based thermoplastic elastomer include a copolymerof an α-olefin such as ethylene, propylene, 1-butene, 1-pentene, and1-octene. Particularly, a polymer of an α-olefin having carbon atoms of3 to 8 and ethylene or propylene, namely, a polymer of an α-olefinhaving carbon atoms of 3 to 8 and ethylene, and a polymer of an α-olefinhaving carbon atoms of 4 to 8 and propylene are preferable.

Specific examples of the olefin-based thermoplastic elastomer include anethylene propylene copolymer (EPR), an ethylene 1-butene copolymer(EBR), an ethylene 1-pentene copolymer, an ethylene 1-octene copolymer(EOR), a propylene 1-butene copolymer (PBR), a propylene 1-pentenecopolymer, a propylene 1-octene copolymer (POR), and the like. Amongthese, EOR, EBR, and EPR are preferable, and EBR and EOR areparticularly preferable.

Examples of the styrene-based thermoplastic elastomer include a blockcopolymer of styrene-based compound and a diene compound, a hydrogenatedpolymer thereof, and the like.

Examples of the styrene-based compound include styrene; an alkyl styrenesuch as α-methyl styrene, p-methyl styrene and p-t-butyl styrene;p-methoxy styrene, vinyl naphthalene, and the like.

Examples of the diene compound include butadiene, isoprene, piperylene,methyl pentadiene, phenyl butadiene, 3,4-dimethyl-1,3-hexadiene,4,5-diethyl-1,3-octadiene, and the like.

Specific examples of the styrene-based thermoplastic elastomer include astyrene butadiene styrene terpolymer (SBS), a styrene isoprene styreneterpolymer (SIS), a styrene ethylene/butylene styrene tetrapolymer(SEBS), a styrene ethylene/propylene styrene tetrapolymer (SEPS), andthe like. Among these, SEBS is preferable.

Examples of the reactive group that can react with the polyamide resininclude an acid anhydride group (—CO—O—OC—), a carboxyl group (—COOH),an epoxy group (—C₂O (i.e., a three-membered ring structure consistingof two carbon atoms and one oxygen atom)), an oxazoline group (—C₃H₄NO),an isocyanate group (—NCO), and the like. The reactive group may beadded to the elastomer using an arbitrary known method.

The reactive group is particularly preferably an acid anhydride group.Examples of a monomer for introducing an acid anhydride group include anacid anhydride such as maleic anhydride, phthalic anhydride, itaconicanhydride, succinic anhydride, glutaric anhydride, adipic anhydride,citraconic anhydride, tetrahydrophthalic anhydride, and butenylsuccinicanhydride. Among these, maleic anhydride, phthalic anhydride, anditaconic anhydride are preferable, and maleic anhydride is particularlypreferable.

These monomers may be used singly or in combination of two or more typesthereof.

In the case of using a modified elastomer into which an acid group(e.g., acid anhydride group) is introduced as the compatibilizer, anacid group content in the modified elastomer is not particularlylimited.

Specific examples of the modified elastomer used as the compatibilizeraccording to the present invention include an anhydrous maleicacid-modified olefin-based thermoplastic elastomer such as anhydrousmaleic acid-modified EPR, anhydrous maleic acid-modified EBR, andanhydrous maleic acid-modified EOR; an anhydrous maleic acid-modifiedstyrene-based thermoplastic elastomer such as anhydrous maleicacid-modified SEBS; and the like. Among these, anhydrous maleicacid-modified EBR, and anhydrous maleic acid-modified EOR arepreferable.

The compatibilizer according to the present invention may be used singlyor in combination of two or more types thereof.

The weight average molecular weight by gel permeation chromatography interms of polystyrene for the compatibilizer is not particularly limited.The weight average molecular weight is preferably in a range from 10,000to 500,000, more preferably from 20,000 to 500,000, and furtherpreferably from 30,000 to 300,000.

1-2. Thermoplastic Resin Composition (I)

Content ratios of a component derived from the polyamide resin, acomponent derived from the polyolefin resin, and a component derivedfrom the compatibilizer in the thermoplastic resin composition (I) ofthe present invention are not particularly limited.

A content ratio of a component derived from the polyamide resin ispreferably in a range from 1% to 90% by mass, more preferably from 10%to 50% by mass, and further preferably from 15% to 30% by mass withrespect to 100% by mass of the sum of the polyamide resin, thepolyolefin resin, and the compatibilizer.

A content ratio of a component derived from the polyolefin resin ispreferably in a range from 1% to 90% by mass, more preferably from 10%to 80% by mass, and further preferably from 40% to 70% by mass withrespect to 100% by mass of the sum of the polyamide resin, thepolyolefin resin, and the compatibilizer.

A content ratio of a component derived from the compatibilizer ispreferably in a range from 1% to 50% by mass, more preferably from 3% to40% by mass, and further preferably from 5% to 30% by mass with respectto 100% by mass of a sum of the polyamide resin, the polyolefin resin,and the compatibilizer.

In the thermoplastic resin composition (I), the polyamide resin isdispersed in the polyolefin resin. It is preferable that the polyamideresin dispersed in the polyolefin resin has as small a particle size aspossible. Specifically, it is preferable that the polyamide resin isfinely dispersed in the polyolefin resin which is a matrix phase.

The particle size of the polyamide resin dispersed in the polyolefinresin is preferably in a range from 10 to 20,000 nm, more preferablyfrom 50 to 10,000 nm, and further preferably from 100 to 5,000 nm.

The particle size and the like can be measured based on images obtainedusing an electron microscope or the like.

The thermoplastic resin composition (I) is obtained by molten blending apolyolefin resin, and a mixed resin which is obtained by molten blendinga polyamide resin and a compatibilizer.

The “mixed resin” will be described in detail with reference to aproduction method of the thermoplastic resin composition (I) below. Themolten blending of the mixed resin and the polyolefin resin will also bedescribed in detail with reference to a production method of thethermoplastic resin composition (I) below.

2. Production Method of Thermoplastic Resin Composition (I)

The production method of the thermoplastic resin composition (I) of thepresent invention is a production method of the thermoplastic resincomposition (I) in which a polyamide resin is dispersed in a polyolefinresin, and is characterized in that the method has a mixing process inwhich an olefin resin and a mixed resin obtained by molten blending apolyamide resin and a compatibilizer are subjected to molten blending,and that the compatibilizer is a modified elastomer in which a reactivegroup that reacts with the polyamide resin is substituted to anelastomer.

2-1 Raw Material

The above explanation about the “polyolefin resin”, “polyamide resin”,and “compatibilizer” can be applied hereto.

2-2. Mixing Process

The mixing process is a step of molten blending a polyolefin resin and amixed resin obtained by mixing a polyamide resin and a compatibilizer.

When the mixed resin obtained by molten blending the polyamide resin andthe compatibilizer in advance is used, the function of thecompatibilizer can be more effectively. It is considered that asituation in which the compatibilizer is independently dispersed in thepolyolefin resin without achieving its function can be suppressed bymixing the compatibilizer with the polyamide resin (dispersion phase) inadvance.

The mixed resin may be solidified by pelletization or the like, or maybe melt.

The mixed resin may be obtained by melt-mixing the polyamide resin andthe compatibilizer using a mixing device such as an extruder (e.g.,single-screw extruder or twin-screw extruder), a kneader, and a mixer(e.g., high-speed flow mixer, puddle mixer, or ribbon mixer). Thesemixing devices may be used either alone or in combination. In the caseof using two or more mixing devices, the mixing devices may be operatedcontinuously, or may be operated batch type. The polyamide resin and thecompatibilizer may be mixed at a time, or may be mixed while adding thepolyamide resin or the compatibilizer in parts (multi-step addition).

The mixing temperature employed when molten blending the polyamide resinand the compatibilizer is not particularly limited. The mixingtemperature may be appropriately adjusted corresponding to the type ofeach component. It is particularly preferable to mix the polyamide resinand the compatibilizer in a state in which each compound is melted. Themixing temperature is specifically in a range from 190° C. to 350° C.,preferably from 200° C. to 330° C., and more preferably 205° C. to 310°C.

In the mixing process, the molten blending can be conducted using amixing device such as an extruder (e.g., single-screw extruder ortwin-screw extruder), a kneader, and a mixer (e.g., high-speed flowmixer, puddle mixer, or ribbon mixer). These mixing devices may be usedeither alone or in combination. In the case of using two or more mixingdevices, the mixing devices may be operated continuously, or may beoperated batch type. The first mixed resin and the polyolefin resin maybe mixed at a time, or may be mixed while adding the components in parts(multi-step addition).

The mixing temperature employed in the mixing process is notparticularly limited as long as the components can be molten blended.The mixing temperature may be appropriately adjusted corresponding tothe type of each component. It is particularly preferable to mix thecomponents in a state in which the compounds are melted. The mixingtemperature is specifically in a range from 190° C. to 350° C.,preferably from 200° C. to 330° C., and more preferably 205° C. to 310°C.

The mixing process may be implemented by (1) molten blending thepolyolefin resin with the mixed resin that is solidified bypelletization or the like in advance, or (2) molten blending thepolyamide resin and the compatibilizer on the upstream side using amulti-step addition-type mixing device or the like, and adding thepolyolefin resin on the downstream side within the device to mix thepolyolefin resin and a melt-mixture (mixed resin) of the polyamide resinand the compatibilizer.

Mixing ratios of the polyamide resin, the polyolefin resin, and thecompatibilizer in the production method of the thermoplastic resincomposition (I) in the present invention are not particularly limited.

A mixing ratio of the polyamide resin is preferably in a range from 1%to 90% by mass, more preferably from 10% to 50% by mass, and furtherpreferably from 15% to 30% by mass with respect to 100% by mass of atotal of the polyamide resin, the polyolefin resin, and thecompatibilizer.

A mixing ratio of the polyolefin resin is preferably in a range from 1%to 90% by mass, more preferably from 10% to 80% by mass, and furtherpreferably from 40% to 90% by mass with respect to 100% by mass of atotal of the polyamide resin, the polyolefin resin, and thecompatibilizer.

A mixing ratio of the compatibilizer is preferably in a range from 1% to50% by mass, more preferably from 3% to 40% by mass, and furtherpreferably from 5% to 30% by mass with respect to 100% by mass of atotal of the polyamide resin, the polyolefin resin, and thecompatibilizer.

The thermoplastic resin composition of the present invention may containcomponents other than the polyamide resin, the polyolefin resin, and thecompatibilizer within a range that does not impede the object of theinvention. Examples of the other components include thermoplastic resinsother than the above-described ones, a flame retardant, a flameretardant aid, fillers, a coloring agent, an antibacterial agent, ananti-static agent, and the like. These components may be used singly orin combination of two or more types thereof.

Examples of the other thermoplastic resins include a polyester-basedresin such as polybutylene terephthalate, polyethylene terephthalate,polycarbonate, polybutylene succinate, polyethylene succinate and polylactic acid; and the like.

Examples of the flame retardant include a halogen-based flame retardantsuch as a halogenated aromatic compound; a phosphorus-based flameretardant such as a nitrogen-containing phosphate compound and aphosphate ester; a nitrogen-based flame retardant such as guanidine,triazine, melamine, and derivatives thereof; an inorganic flameretardant such as a metal hydroxide; a boron-based flame retardant; asilicone-based flame retardant; a sulfur-based flame retardant; a redphosphorus-based flame retardant; and the like.

Examples of the flame retardant aid include various antimony compounds,metal compounds containing zinc, metal compounds containing bismuth,magnesium hydroxide, clayey silicates, and the like.

Examples of the fillers include glass components including a glassfiber, glass beads, a glass flake, and the like; silica; an inorganicfiber such as a glass fiber, an alumina fiber, and a carbon fiber;graphite; a silicic acid compound such as calcium silicate, aluminumsilicate, kaolin, talc, and clay; a metal oxide such as iron oxide,titanium oxide, zinc oxide, antimony oxide, and alumina; a carbonate orsulfate of a metal such as calcium, magnesium, and zinc; an organicfiber such as an aromatic polyester fiber, an aromatic polyamide fiber,a fluoric resin fiber, a polyimide fiber, and a vegetable fiber; and thelike.

Examples of the colorant include pigments and dyes.

3. Molded Article

The thermoplastic resin composition (I) of the present invention may beformed using an optionally method. The shape, size, thickness, and thelike of the resulting molded article are not particularly limited.Application use thereof is not particularly limited. The molded articleis used as an exterior material, an interior material, or a structuralmaterial for automobiles, rail vehicles, ships, airplanes, and the like.Examples of the automotive materials include an automotive exteriormaterial, an automotive interior material, an automotive structuralmaterial, an engine room part, and the like. Specific examples of theautomotive materials include a bumper, a spoiler, a cowling, a frontgrille, a garnish, a bonnet, a trunk lid, a fender panel, a door panel,a roof panel, an instrument panel, a door trim, a quarter trim, a rooflining, a pillar garnish, a deck trim, a tonneau board, a package tray,a dashboard, a console box, a kicking plate, a switch base, a sheetbackboard, a sheet frame, an armrest, a sun visor, an intake manifold,an engine head cover, an engine under cover, an oil filter housing, ahousing of an on-board electronic device (e.g., ECU or TV monitor), anair filter box, and the like. The molded article may also be used as aninterior material, an exterior material, and a structural material usedfor buildings, furniture, and the like. For example, the molded articlemay be used as a door mounting material, a door structural material, afurniture (e.g., desk, chair, shelf, or chest of drawers)mounting/structural material, and the like. The molded article may alsobe used as a package, a container (e.g., tray), a protective member, apartition member, and the like. The molded article may also be used as ahousing and a structural member of home appliances (e.g., flat TV,refrigerator, washing machine, cleaner, mobile phone, portable gamemachine, and notebook-sized personal computer).

4. Thermoplastic Resin Composition (II)

The plant-derived polyamide resin containing thermoplastic resincomposition of the present invention is characterized in that thethermoplastic resin composition is obtained by molten blending thepolyamide resin, a polyolefin resin, and a compatibilizer, that thepolyamide resin is at least one plant-derived polyamide resin selectedfrom a group consisting of polyamide 11, polyamide 610, polyamide 614,polyamide 1010, and polyamide 10T, that a content of the polyamide resinis in a range from 1% to 80% by mass based on 100% by mass of a total ofthe three components, that a content of the polyolefin resin is in arange from 5% to 75% by mass based on 100% by mass of a total of thethree components, that the compatibilizer is an acid-modifiedolefin-based thermoplastic elastomer, and that a content of thecompatibilizer is in a range from 1% to 30% by mass based on 100% bymass of a total of the three components.

Hereinafter, this themoplastic resin composition may be referred to as“thermoplastic resin composition (II)”.

Components

(1) Polyamide Resin

The polyamide resin is a polymer having a chain-like skeleton formed bypolymerizing a plurality of monomers through an amide bond (—NH—CO—). Inthe thermoplastic resin composition (II) according to the presentinvention, the polyamide resin is at least one polyamide resin selectedfrom polyamide 11 (hereinafter may be simply referred to as “PA11”),polyamide 610 (hereinafter may be simply referred to as “PA610”),polyamide 614 (hereinafter may be simply referred to as “PA614”),polyamide 1010 (hereinafter may be simply referred to as “PA1010”), andpolyamide 10T (hereinafter may be simply referred to as “PA10T”).

PA11 is a polyamide resin having a structure in which monomers having 11carbon atoms are bonded through an amide bond. PA11 is normally obtainedusing aminoundecanoic acid or undecanelactam as a monomer. Sinceaminoundecanoic acid is a monomer obtained from castor oil, PA11 isdesirable from the viewpoint of environmental protection (particularlyfrom the viewpoint of carbon neutral). A content of a structural unitderived from the monomer having 11 carbon atoms in PA11 is preferably50% or more based on the total structural units and may be 100%.

PA610 is a polyamide resin having a structure in which a monomer having6 carbon atoms and a monomer having 10 carbon atoms are bonded throughan amide bond. PA610 is normally obtained by copolymerizing a diamineand a dicarboxylic acid. Hexamethylenediamine and sebacic acid arerespectively used as the diamine and the dicarboxylic acid. Sincesebacic acid is a monomer obtained from castor oil, PA610 is desirablefrom the viewpoint of environmental protection (particularly from theviewpoint of carbon neutral). A total content of a structural unitderived from the monomer having 6 carbon atoms and a structural unitderived from the monomer having 10 carbon atoms in PA610 is preferably50% or more based on the total structural units and may be 100%.

PA1010 is a polyamide resin having a structure in which a diamine having10 carbon atoms and a dicarboxylic acid having 10 carbon atoms arecopolymerized. PA1010 is normally obtained using 1,10-decanediamine(decamethylenediamine) and sebacic acid. Since decamethylenediamine andsebacic acid are monomers obtained from castor oil, PA1010 is desirablefrom the viewpoint of environmental protection (particularly from theviewpoint of carbon neutral). A total content of a structural unitderived from the diamine having 10 carbon atoms and a structural unitderived from the dicarboxylic acid having 10 carbon atoms in PA1010 ispreferably 50% or more based on the total structural units and may be100%.

PA614 is a polyamide resin having a structure in which a monomer having6 carbon atoms and a monomer having 14 carbon atoms are bonded throughan amide bond. PA614 is normally obtained by copolymerizing a diamine(specifically hexamethylenediamine) and a plant-derived dicarboxylicacid having 14 carbon atoms. Since the plant-derived dicarboxylic acidis used, PA614 is desirable from the viewpoint of environmentalprotection (particularly from the viewpoint of carbon neutral). A totalcontent of a structural unit derived from the monomer having 6 carbonatoms and a structural unit derived from the monomer having 14 carbonatoms in PA614 is preferably 50% or more based on the total structuralunits and may be 100%.

PA10T is a polyamide resin having a structure in which a diamine having10 carbon atoms and terephthalic acid are bonded through an amide bond.PA10T is normally obtained using 1,10-decanediamine(decamethylenediamine) and terephthalic acid. Since decamethylenediamineis a monomer obtained from castor oil, PA10T is desirable from theviewpoint of environmental protection (particularly from the viewpointof carbon neutral). A total content of a structural unit derived fromthe diamine having 10 carbon atoms and a structural unit derived fromterephthalic acid in PA10T is preferably 50% or more based on the totalstructural units and may be 100%.

Among the above five plant-derived polyamide resins, PA11 is superior tothe other plant-derived polyamide resins from the viewpoint of low waterabsorption, low density, and high plant-derived content.

PA610 is inferior to PA11 as to water absorption, chemical resistance,and impact strength, but is superior to PA11 from the viewpoint of heatresistance (melting point) and rigidity (strength). Since PA610 exhibitslow water absorption and high dimensional stability as compared withpolyamide 6 and polyamide 66, PA610 can be used as an alternative topolyamide 6 and polyamide 66.

PA1010 is superior to PA11 from the viewpoint of heat resistance andrigidity. PA1010 has a plant-derived content almost equal to that ofPA11, and may be used for parts for which durability is desired.

Since PA10T includes an aromatic ring in the molecular skeleton, PA10Thas a high melting point and high rigidity as compared with PA1010.Therefore, PA10T can be used under a severe environment (e.g., a partfor which high heat resistance or input resistance is required).

A content of the polyamide resin (plant-derived polyamide resin) is in arange from 1% to 80% by mass based on 100% by mass of a total content ofthe polyamide resin, the polyolefin resin, and the compatibilizer. Whenthe content of the polyamide resin is within the above range, it ispossible to obtain a molded article that is excellent in impact strengthas well as rigidity. The content of the polyamide resin is preferably ina range from 10% to 40% by mass. When the content of the polyamide resinis within the above range, the polyolefin resin serves as a matrixphase, the polyamide resin (plant-derived polyamide resin) serves as adispersed phase, and the polyamide resin can be micro-dispersed in thematrix phase. Moreover, a specific gravity of the entire thermoplasticresin composition (II) can be reduced by reducing the amount of thepolyamide resin having a high specific gravity. This makes it possibleto obtain a molded article that has a reduced weight, and exhibitsexcellent impact strength and excellent rigidity. The content of thepolyamide resin is more preferably in a range from 10% to 35% by mass,and particularly from 10% to 30% by mass.

(2) Polyolefin Resin

The polyolefin resin is an olefin homopolymer and/or an olefincopolymer. Examples of the olefin include ethylene, propylene, 1-butene,3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene,1-hexene, 1-octene, and the like.

Examples of the polyolefin resin include polyethylene resin,polypropylene resin, poly(1-butene), poly(1-hexene),poly(4-methyl-1-pentene), and the like. These polymers may be usedsingly or in combination of two or more types thereof. The polyolefinresin may be a mixture of these polymers.

Examples of the polyethylene resin include an ethylene homopolymer, anda copolymer of ethylene and another olefin. Examples of the copolymer ofethylene and another olefin include ethylene 1-butene copolymer,ethylene 1-hexene copolymer, ethylene 1-octene copolymer, ethylene4-methyl-1-pentene copolymer, and the like. Note that units derived fromethylene account for 50% or more of the total structural units includedin these copolymers.

Examples of the polypropylene resin include propylene homopolymer,propylene ethylene copolymer, propylene 1-butene copolymer, and thelike. Note that units derived from propylene account for 50% or more ofthe total structural units included in these copolymers.

Among these, the polyethylene resin and the polypropylene resin arepreferable, and the polypropylene resin is particularly preferable fromthe viewpoint of impact strength. The polypropylene resin may be a mixedresin of a polypropylene resin and a polyethylene resin. In this case, acontent ratio of the polypropylene resin is 50% or more by mass based on100% by mass of a total content of the polypropylene resin and thepolyethylene resin.

The weight average molecular weight by GPC in terms of polystyrene forthe polyolefin resin is not particularly limited. The weight averagemolecular weight is preferably in a range from 10,000 to 500,000, morepreferably from 100,000 to 450,000, and further preferably from 200,000to 400,000.

A content of the polyolefin resin is in a range from 5% to 75% by massbased on 100% by mass of a total content of the polyamide resin(plant-derived polyamide resin), the polyolefin resin, and thecompatibilizer. When the content of the polyolefin resin is within theabove range, it is possible to obtain a molded article that is excellentin impact strength as well as rigidity. The content of the polyolefinresin is preferably in a range from 50% to 75% by mass. When the contentof the polyolefin resin is within the above range, the polyolefin resinserves as a matrix phase, the polyamide resin (plant-derived polyamideresin) serves as a dispersed phase, and the polyamide resin can bemicro-dispersed in the matrix phase. Moreover, a specific gravity of theentire thermoplastic resin composition (II) can be reduced by reducingthe amount of the polyamide resin having a high specific gravity. Thismakes it possible to obtain a molded article that has a reduced weight,and exhibits excellent impact strength and excellent rigidity. Thecontent of the polyolefin resin is more preferably in a range from 52.5%to 75% by mass, and particularly from 55% to 70% by mass.

Since the content of the polyamide resin can be reduced whilesufficiently maintaining the mechanical properties, the surfaceglossiness of the resulting molded article can be reduced (i.e., a goodexternal appearance can be obtained). Therefore, the molded article canbe applied to an exterior material or an interior material that isobserved directly, and excellent design can be implemented.

The polyolefin resin is a polyolefin which does not have an affinitywith the polyamide resin and does not have a reactive group that reactswith the polyamide resin either. Thus, the polyolefin resin is differentfrom a polyolefin-based component as the compatibilizer to be describedbelow.

(3) Compatibilizer

The compatibilizer is an acid-modified olefin-based thermoplasticelastomer. Specifically, the compatibilizer is a modified elastomerobtained by introducing an acid group that can interact with thepolyamide resin into an olefin-based thermoplastic elastomer.

Examples of the olefin-based thermoplastic elastomer include anelastomer obtained by copolymerizing two or more olefins. Examples ofthe olefin include ethylene, propylene, an α-olefin having 4 to 8 carbonatoms, and the like. Examples of the α-olefin having 4 to 8 carbon atomsinclude 1-butene, 3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene,4-methyl-1-pentene, 1-hexene, 1-octene, and the like.

Among these, a copolymer of ethylene and an α-olefin having 3 to 8carbon atoms, and a copolymer of propylene and an α-olefin having 4 to 8carbon atoms are preferable as the olefin-based thermoplastic elastomer.

Examples of the copolymer of ethylene and an α-olefin having 3 to 8carbon atoms include an ethylene propylene copolymer (EPR), an ethylene1-butene copolymer (EBR), an ethylene 1-pentene copolymer, and anethylene 1-octene copolymer (EOR). Examples of the copolymer ofpropylene and an α-olefin having 4 to 8 carbon atoms include a propylene1-butene copolymer (PBR), a propylene 1-pentene copolymer, a propylene1-octene copolymer (POR), and the like. Among these, EPR, EBR, and EORare preferable, and EBR and EOR are more preferable.

Examples of the acid group that is introduced into the olefin-basedthermoplastic elastomer include an acid anhydride group (—CO—O—OC—)and/or a carboxyl group (—COOH), and the like. The acid group (reactivegroup) may be introduced into the elastomer using an arbitrary knownmethod.

The acid group is particularly preferably an acid anhydride group.Examples of a monomer for introducing an acid anhydride group include anacid anhydride such as maleic anhydride, phthalic anhydride, itaconicanhydride, succinic anhydride, glutaric anhydride, adipic anhydride,citraconic anhydride, tetrahydrophthalic anhydride, and butenylsuccinicanhydride. Among these, maleic anhydride, phthalic anhydride, anditaconic anhydride are preferable, and maleic anhydride is particularlypreferable.

These monomers may be used singly or in combination of two or more typesthereof.

Specifically, an anhydrous maleic acid-modified ethylene 1-butenecopolymer and an anhydrous maleic acid-modified ethylene octenecopolymer are particularly preferable as the acid-modified olefin-basedthermoplastic elastomer. When these compatibilizers are used, it ispossible to implement excellent impact strength and excellent rigidityin combination while achieving a low specific gravity, being favorable.

In the case of using an olefin-based thermoplastic elastomer into whichan acid group (e.g., acid anhydride group) is introduced as thecompatibilizer, an acid group content in the olefin-based thermoplasticelastomer is not particularly limited.

A content of the compatibilizer is in a range from 1% to 30% by massbased on 100% by mass of a total content of the polyamide resin(plant-derived polyamide resin), the polyolefin resin, and thecompatibilizer. When the content of the compatibilizer is within theabove range, it is possible to obtain a molded article that is excellentin impact strength as well as rigidity. The content of thecompatibilizer is preferably in a range from 5% to 30% by mass. When thecontent of the compatibilizer is within the above range, the polyolefinresin serves as a matrix phase, the polyamide resin (plant-derivedpolyamide resin) serves as a dispersed phase, and the polyamide resincan be micro-dispersed in the matrix phase. Moreover, this makes itpossible to obtain a molded article that exhibits excellent impactstrength and excellent rigidity. The content of the compatibilizer ismore preferably in a range from 10% to 30% by mass, and particularlyfrom 10% to 25% by mass.

The thermoplastic resin composition (II) that utilizes the plant-derivedpolyamide resin in the present invention exhibits excellent flowability.In particular, the thermoplastic resin composition (II) exhibitsexcellent flowability and excellent formability when the content of thepolyamide resin is in a range from 10% to 40% by mass, the content ofthe polyolefin resin is in a range from 50% to 75% by mass, and thecontent of the acid-modified olefin-based thermoplastic elastomer is ina range from 5% to 30% by mass.

A specific gravity of the thermoplastic resin composition (II) thatutilizes the plant-derived polyamide resin in the present invention isnot particularly limited, but may normally be 1.05 or less. Inparticular, the specific gravity thereof may be in a range from 0.89 to1.05, and be preferably from 0.92 to 0.98 when the content of polyamide11 is in a range from 1% to 40% by mass %, the content of apolypropylene resin is in a range from 50% to 75% by mass, and thecontent of the anhydrous maleic acid-modified olefin-based thermoplasticelastomer is in a range from 5% to 30% by mass. Specifically, thethermoplastic resin composition (II) that utilizes the plant-derivedpolyamide resin in the present invention may have a specific gravityalmost equal to those of a polyethylene resin and a polypropylene resin,but exhibits remarkably excellent impact strength and rigidity ascompared with a polyethylene resin or a polypropylene resin.

(4) Other Components

The thermoplastic resin composition (II) that utilizes the plant-derivedpolyamide of the present invention resin may contain components otherthan the polyamide resin, the polyolefin resin, and the compatibilizer.

The polyamide resin is the above-mentioned plant-derived polyamideresin, however, the thermoplastic resin composition (II) of the presentinvention may include an additional polyamide resin other than thepolyamide resin that is selected from the plant-derived polyamide resinsas long as the object of the invention is not impaired.

The other polyamide resin can be prepared by polycondensation of adiamine and a dicarboxylic acid. Examples of the diamine used as themonomer include an aliphatic diamine such as ethylenediamine,1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane,1,7-diaminoheptane, 1,8-diaminooctane, 1,9-diaminononane,1,11-diaminoundecane, 1,12-diaminododecane, 1,13-diaminotridecane,1,14-diaminotetradecane, 1,15-diaminopentadecane,1,16-diaminohexadecane, 1,17-diaminoheptadecane, 1,18-diaminooctadecane,1,19-diaminononadecane, 1,20-diaminoeicosane,2-methyl-1,5-diaminopentane, and 2-methyl-1,8-diaminooctane; analicyclic diamine such as cyclohexanediamine andbis(4-aminocyclohexyl)methane; an aromatic diamine such as axylylenediamine (e.g., p-phenylenediamine and m-phenylenediamine); andthe like. These compounds may be used singly or in combination of two ormore types thereof.

Examples of the dicarboxylic acid used as the monomer include analiphatic dicarboxylic acid such as oxalic acid, malonic acid, succinicacid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaicacid, undecanedioic acid, dodecanedioic acid, brasylic acid,tetradecanedioic acid, pentadecanedioic acid, and octadecanedioic acid;an alicyclic dicarboxylic acid such as cyclohexanedicarboxylic acid; anaromatic dicarboxylic acid such as phthalic acid, terephthalic acid,isophthalic acid, and napthalenedicarboxylic acid; and the like. Thesecompounds may be used singly or in combination of two or more typesthereof.

Examples of the other polyamide resin include polyamide 6, polyamide 66,polyamide 612, polyamide 12, polyamide 6T, polyamide 6I, polyamide 9T,polyamide M5T, and the like. These other polyamide resins may be usedsingly or in combination of two or more types thereof. In the case ofcontaining the other polyamide resin, a content thereof is less than 40%by mass based on 100% by mass of a total content the polyamide resin(plant-derived polyamide resin) and the other polyamide resin.

It is preferable that the other polyamide resin have a structure inwhich half or more (50% or more) of the carbon atoms that form the mainchain form a chain-like skeleton. Specifically, when the other polyamideresin has an aromatic skeleton, it is preferable that less than half(less than 50%) of the carbon atoms that form the main chain form thearomatic skeleton.

The compatibilizer is an acid-modified olefin-based thermoplasticelastomer, however, the thermoplastic resin composition (II) of thepresent invention may include an additional compatibilizer other thanthe compatibilizer that is the acid-modified olefin-based thermoplasticelastomer as long as the object of the invention is not impaired.

For example, a modified thermoplastic elastomer to which a reactivegroup that can react with the polyamide resin may be used as a modifiedthermoplastic elastomer other than the acid-modified olefin-basedthermoplastic elastomer. An olefin-based thermoplastic elastomer and astyrene-based thermoplastic elastomer are preferable as thethermoplastic elastomer used as the other thermoplastic elastomer.

Examples of the olefin-based thermoplastic elastomer include thosementioned above. Examples of the styrene-based thermoplastic elastomerinclude a block copolymer of a styrene-based compound and a conjugateddiene compound, and a hydrogenated product thereof.

Examples of the styrene-based compound include styrene; an alkyl styrenesuch as α-methyl styrene, p-methyl styrene and p-t-butyl styrene;p-methoxy styrene, vinyl naphthalene, and the like.

Examples of the diene compound include butadiene, isoprene, piperylene,methyl pentadiene, phenyl butadiene, 3,4-dimethyl-1,3-hexadiene,4,5-diethyl-1,3-octadiene, and the like.

Specific examples of the styrene-based thermoplastic elastomer include astyrene butadiene styrene terpolymer (SBS), a styrene isoprene styreneterpolymer (SIS), a styrene ethylene/butylene styrene tetrapolymer(SEBS), a styrene ethylene/propylene styrene tetrapolymer (SEPS), andthe like.

Examples of the reactive group that can react with the polyamide resininclude an acid anhydride group (—CO—O—OC—), a carboxyl group (—COOH),an epoxy group (—C₂O (i.e., a three-membered ring structure consistingof two carbon atoms and one oxygen atom)), an oxazoline group (—C₃H₄NO),an isocyanate group (—NCO), and the like. The reactive group may beadded to the elastomer using an arbitrary known method.

Specifically, examples of the other compatibilizer include anepoxy-modified olefin-based thermoplastic elastomer, an acid-modifiedstyrene-based thermoplastic elastomer, an epoxy-modified styrene-basedthermoplastic elastomer, and the like. Examples of the acid-modifiedstyrene-based thermoplastic elastomer include an anhydrous maleicacid-modified styrene-based thermoplastic elastomer such as an anhydrousmaleic acid-modified SEBS. These other compatibilizers may be usedsingly or in combination of two or more types thereof.

Further a thermoplastic resin other than the polyamide resin, thepolyolefin resin, and the compatibilizer, a flame retardant, a flameretardant aid, a filler, a coloring agent, an antibacterial agent, anantistatic agent, and the like may be exemplified. These components maybe used singly or in combination of two or more types thereof.

Examples of the other thermoplastic resins include a polyester-basedresin such as polybutylene terephthalate, polyethylene terephthalate,polycarbonate, polybutylene succinate, polyethylene succinate and polylactic acid; and the like.

Examples of the flame retardant include a halogen-based flame retardantsuch as a halogenated aromatic compound; a phosphorus-based flameretardant such as a nitrogen-containing phosphate compound and aphosphate ester; a nitrogen-based flame retardant such as guanidine,triazine, melamine, and derivatives thereof; an inorganic flameretardant such as a metal hydroxide; a boron-based flame retardant; asilicone-based flame retardant; a sulfur-based flame retardant; a redphosphorus-based flame retardant; and the like.

Examples of the flame retardant aid include various antimony compounds,metal compounds containing zinc, metal compounds containing bismuth,magnesium hydroxide, clayey silicates, and the like.

Examples of the fillers include glass components including a glassfiber, glass beads, a glass flake, and the like; silica; an inorganicfiber such as a glass fiber, an alumina fiber, and a carbon fiber;graphite; a silicic acid compound such as calcium silicate, aluminumsilicate, kaolin, talc, and clay; a metal oxide such as iron oxide,titanium oxide, zinc oxide, antimony oxide, and alumina; a carbonate orsulfate of a metal such as calcium, magnesium, and zinc; an organicfiber such as an aromatic polyester fiber, an aromatic polyamide fiber,a fluoric resin fiber, a polyimide fiber, and a vegetable fiber; and thelike.

Examples of the coloring agent include pigments and dyes.

5. Production Method

The thermoplastic resin composition (II) that utilizes the plant-derivedpolyamide resin in the present invention is not particularly limited andcan be produced by mixing a polyamide resin, a polyolefin resin, and acompatibilizer. For example, the thermoplastic resin composition (II)may be obtained by (1) mixing a polyamide resin, a polyolefin resin, anda compatibilizer at a same time, (2) mixing a polyolefin resin and amixed resin obtained by mixing a polyamide resin and a compatibilizer,or (3) mixing a polyamide resin and a mixed resin obtained by mixing apolyolefin resin and a compatibilizer. In the case of applying themethod (2), more excellent impact strength and rigidity can be obtainedas compared with the methods (1) and (3) even when the amount of eachcomponent is identical.

The mixing method used in each process is not particularly limited. Forexample, the mixing process may be performed using a mixing device suchas an extruder (e.g., single-screw extruder or twin-screw extruder), akneader, and a mixer (e.g., high-speed flow mixer, puddle mixer, orribbon mixer). These mixing devices may be used either alone or incombination. In the case of using two or more mixing devices, the mixingdevices may be operated continuously, or may be operated batch type.

The components may be mixed at a time, or may be mixed while adding thecomponents in parts (multi-step addition).

The mixing temperature employed in the mixing process is notparticularly limited as long as the components can be molten blended.The mixing temperature may be appropriately adjusted corresponding tothe type of each component. It is particularly preferable to mix thecomponents in a state in which the thermoplastic resin is melted. Themixing temperature is specifically in a range from 190° C. to 350° C.,preferably from 200° C. to 330° C., and more preferably 205° C. to 310°C.

6. Molded Article

The thermoplastic resin composition (II) obtained by the above methodmay be formed using an arbitrary method. The shape, size, thickness, andthe like of the resulting molded article are not particularly limited.Application use thereof is not particularly limited.

The molded article of the present invention is used as an exteriormaterial, an interior material, or a structural material forautomobiles, rail vehicles, ships, airplanes, and the like. Examples ofthe automotive materials include an automotive exterior material, anautomotive interior material, an automotive structural material, anengine room part, and the like. Specific examples of the automotivematerials include a bumper, a spoiler, a cowling, a front grille, agarnish, a bonnet, a trunk lid, a fender panel, a door panel, a roofpanel, an instrument panel, a door trim, a quarter trim, a roof lining,a pillar garnish, a deck trim, a tonneau board, a package tray, adashboard, a console box, a kicking plate, a switch base, a sheetbackboard, a sheet frame, an armrest, a sun visor, an intake manifold,an engine head cover, an engine under cover, an oil filter housing, anair filter box, an ECU box, a housing of an on-board electronic device(e.g., TV monitor), and the like.

Further, the molded article may also be used as a housing or astructural member of home appliances (e.g., flat TV, refrigerator,washing machine, cleaner), a mobile phone, a portable game machine, alaptop computer, or the like.

In addition, the molded article is used as an interior material, anexterior material, or a structural material used for buildings,furniture, and the like. For example, the molded article may be used asa door mounting material, a door structural material, a furniture (e.g.,desk, chair, shelf, or chest of drawers) mounting/structural material,and the like. The molded article may also be used as a package, acontainer (e.g., tray), a protective member, a partition member, and thelike.

EXAMPLES

Hereinafter, the present invention will be described in more detail byway of Examples.

[1-1] Production of Thermoplastic Resin Composition (I) Using PA11 asPolyamide Resin, and Making of Test Piece

Example 1

(1) Preparation of Mixed Resin

PA11 “Rilsan BMN O” (nylon 11 resin, Mw=18,000, mp=190° C.) manufacturedby ARKEMA K.K. was used as a polyamide resin (A). Anhydrous maleicacid-modified EPR “Tafmer MP0620” (MFR=0.3 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C).Each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 1. Subsequently, the mixture was charged into a twinscrew kneading extruder (screw diameter=15 mm, L/D=59) manufactured byTechnovel Corp., and mixed therein under conditions of a kneadingtemperature at 210° C., an extrusion speed at 2.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded mixed resin was then cutusing a pelletizer so as to prepare a mixed resin pellet.

(2) Mixing Process

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin (B)and the previously mixed resin pellet were dry-blended so as to have amixing ratio as listed in Table 1. Subsequently, the mixture was chargedinto a twin screw kneading extruder (screw diameter=15 mm, L/D=59)manufactured by Technovel Corp., and mixed therein under conditions of akneading temperature at 210° C., an extrusion speed at 2.0 kg/hr, andthe number of screw revolution at 200 rpm. An extruded thermoplasticresin composition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Example 1.

After that, the resulting thermoplastic resin composition pellet forExample 1 was put into a hopper of an injection molding machine (40-toninjection molding machine) manufactured by Nissei Plastic Ind., Co.,Ltd., to prepare a test piece for evaluation under conditions of a settemperature at 210° C. and a mold temperature at 60° C.

Example 2

A pellet of thermoplastic resin composition for Example 2 was producedin the same manner as that in Example 1 except that anhydrous maleicacid-modified EBR “Tafmer MH7020” (MFR=1.5 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C)and each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 1. After that, injection molding was carried out in thesame manner as that in Example 1 to prepare a test piece for Example 2.

Example 3

A pellet of thermoplastic resin composition for Example 3 was producedin the same manner as that in Example 1 except that anhydrous maleicacid-modified SEBS “Tuftec M1913” (MFR=5.0 g/10 min. at 230° C.)manufactured by Asahi Kasei Chemicals Corp. was used as a compatibilizer(C) and each pellet thereof was dry-blended so as to have a mixing ratioas listed in Table 1. After that, injection molding was carried out inthe same manner as that in Example 1 to prepare a test piece for Example3.

Example 4

A pellet of thermoplastic resin composition for Example 4 was producedin the same manner as that in Example 1 except that anhydrous maleicacid-modified EOR “AMPLIFY GR216” (Mw=150,000, anhydrous maleicacid-modified content: 0.8 wt %) manufactured by The Dow ChemicalCompany was used as a compatibilizer (C) and each pellet thereof wasdry-blended so as to have a mixing ratio as listed in Table 1. Afterthat, injection molding was carried out in the same manner as that inExample 1 to prepare a test piece for Example 4.

Examples 5 to 18

Pellets of thermoplastic resin compositions for Examples 5 to 18 wereproduced in the same manner as that in Example 1 except that anhydrousmaleic acid-modified EBR “Tafmer MH7020” (MFR=1.5 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C)and each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Tables 1 and 2. After that, injection molding was carried outin the same manner as that in Example 1 to prepare test pieces forExamples 5 to 18.

Comparative Example 1

A pellet of thermoplastic resin composition for Comparative Example 1was produced in the same manner as that in Example 1 except thatanhydrous maleic acid-modified PP “Umex 1001” (Mw=40,000, acid value=26)manufactured by Sanyo Chemical Ind., Ltd. was used as a compatibilizer(C) and each pellet thereof was dry-blended so as to have a mixing ratioas listed in Table 2. After that, injection molding was carried out inthe same manner as that in Example 1 to prepare a test piece forComparative Example 1.

Comparative Example 2

A pellet of thermoplastic resin composition for Comparative Example 2was produced in the same manner as that in Example 1 except thatnon-modified EPR “Tafmer P-0680” (MFR=0.7 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C)and each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 2. After that, injection molding was carried out in thesame manner as that in Example 1 to prepare a test piece for ComparativeExample 2.

Comparative Example 3

A pellet of thermoplastic resin composition for Comparative Example 3was produced in the same manner as that in Example 1 except thatnon-modified EBR “Tafmer A-1070S” (MFR=2.2 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C)and each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 2. After that, injection molding was carried out in thesame manner as that in Example 1 to prepare a test piece for ComparativeExample 3.

Comparative Example 4

A pellet of thermoplastic resin composition for Comparative Example 4was produced in the same manner as that in Example 1 except thatunmodified SEBS “Tuftec H1041” (MFR=5 g/10 min. at 230° C.) manufacturedby Asahi Kasei Chemicals Corp. was used as a compatibilizer (C) and eachpellet thereof was dry-blended so as to have a mixing ratio as listed inTable 2. After that, injection molding was carried out in the samemanner as that in Example 1 to prepare a test piece for ComparativeExample 4.

Comparative Example 5

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin wascharged into a twin screw kneading extruder (screw diameter=15 mm,L/D=59) manufactured by Technovel Corp., and mixed therein underconditions of a kneading temperature at 210° C., an extrusion speed at2.0 kg/hr, and the number of screw revolution at 200 rpm. An extrudedthermoplastic resin composition was then cut using a pelletizer so as toprepare a thermoplastic resin composition pellet for Comparative Example5 (see Table 2). Subsequently, injection molding was carried out in thesame manner as that in Example 1 to prepare a test piece for ComparativeExample 5.

TABLE 1 Example 1 2 3 4 5 6 7 8 9 10 11 12 Mixing (A) Polyamide (PA11)20 20 20 20  5 10 25 30 40 50 60 70 ratio (B) Polyolefin 70 70 70 70 8580 65 60 50 40 30 20 (% by (C) Compati- Anhydrous maleic 10 — — — — — —— — — — — mass) bilizer acid-modified EPR Anhydrous maleic — 10 — — 1010 10 10 10 10 10 10 acid-modified EBR (“Tafmer MH7020”) Anhydrousmaleic — — 10 — — — — — — — — — acid-modified SEBS Anhydrous maleic — —— 10 — — — — — — — — acid-modified EOR Anhydrous maleic — — — — — — — —— — — — acid-modified PP Unmodified EPR — — — — — — — — — — — —Unmodified EBR — — — — — — — — — — — — Unmodified SEBS — — — — — — — — —— — —

TABLE 2 Example Comparative Example 13 14 15 16 17 18 1 2 3 4 5 Mixing(A) Polyamide (PA11) 80 60 60 60 25 25 20 20 20 20 — ratio (B)Polyolefin 10 35 25 20 60 55 70 70 70 70 100 (% by (C) Compati-Anhydrous maleic — — — — — — — — — — — mass) bilizer acid-modified EPRAnhydrous maleic 10  5 15 20 15 20 — — — — — acid-modified EBR (“TAFMERMH7020”) Anhydrous maleic — — — — — — — — — — — acid-modified SEBSAnhydrous maleic — — — — — — — — — — — acid-modified EOR Anhydrousmaleic — — — — — — 10 — — — — acid-modified PP Unmodified EPR — — — — —— — 10 — — — Unmodified EBR — — — — — — — — 10 — — Unmodified SEBS — — —— — — — — — 10 —[1-2] Evaluation of Thermoplastic Resin Composition (I) (Examples 1 to18 and Comparative Examples 1 to 5)(1) Measurement of Charpy Impact Strength

Test pieces for evaluation obtained in Examples 1 to 18 and ComparativeExamples 1 to 5 of the above section [1-1] were subjected to measurementin accordance with JIS K7111-1 for Charpy impact strength. Resultsthereof were shown in Table 3, FIG. 1 (Examples 1 to 4 and ComparativeExamples 1 to 4), and FIG. 2 (Examples 1 to 4 and Comparative Examples 1to 4). In the measurement of Charpy impact strength, the impact strengthwas measured by an edgewise test method at a temperature of 23° C. witha test piece having notch (type A).

(2) Measurement of Flexural Modulus

Test pieces for evaluation obtained in Examples 1 to 18 and ComparativeExamples 1 to 5 of the above section [1-1] were subjected to measurementin accordance with JIS K7171 for flexural modulus. Results thereof wereshown in Table 3. The flexural modulus was measured by supporting eachof test pieces at two points (radius of curvature: 5 mm) with a distanceL of 64 mm therebetween while applying a load at a speed of 2 mm/minfrom an action point (radius of curvature: 5 mm) positioned in themiddle of the two points.

(3) Observation of Morphology

A fracture surface of the test piece according to Example 2 provided forthe measurement of Charpy impact strength in the above item (1) of thesection [1-2] was observed with a scanning electron microscope(manufactured by JEOL Ltd.) by fifty hundred magnification. The imagewas shown in FIG. 3.

TABLE 3 Charpy impact Flexural strength (kJ/m²) modulus (MPa) Example 16.5 1238 2 10.1 1241 3 7.0 1199 4 9.2 1117 5 6.6 1078 6 8.0 1046 7 8.81184 8 9.5 1182 9 10.3 1148 10 18.2 1062 11 62.0 946 12 25.6 927 13 72.1866 14 6.4 1211 15 80.0 852 16 86.3 710 17 17.9 952 18 72.9 775Comparative 1 1.4 1386 Example 2 2.7 1251 3 4.2 1352 4 2.8 1309 5 2.481476[1-3] Effects of Examples 1 to 18

According to the results in Table 3, Comparative Examples 1 to 4 inwhich the modified polypropylene or the unmodified elastomer was used asthe compatibilizer had flexural moduli of 1,251 to 1,386 MPa, but Charpyimpact strengths were as low as 1.4 to 4.2 kJ/m². Comparative Example 5in which the polyamide resin and the compatibilizer were not used hadflexural modulus of 1,476 MPa, but Charpy impact strengths were as lowas 2.48 kJ/m².

On the other hand, Examples 1 to 18 in which the modified elastomer wasused as the compatibilizer had flexural moduli of 710 to 1,241 MPa, andCharpy impact strengths of 6.4 to 86.3 kJ/m². It was found that Examples1 to 18 were excellent in impact strength as well as rigidity.

Clearly from the results in FIG. 1 and Table 3, it was confirmed thatimpact strength could be improved while maintaining sufficient rigiditywhen an elastomer was modified.

Specifically, while Charpy impact strength achieved by ComparativeExample 2 in which unmodified EPR was used as the compatibilizer was 2.7kJ/m², Charpy impact strength achieved by Example 1 in which anhydrousmaleic acid-modified EPR was used as the compatibilizer was 6.5 kJ/m². Asignificantly improvement in impact strength was obtained. Additionally,while Charpy impact strength achieved by Comparative Example 3 in whichunmodified EBR was used as the compatibilizer was 4.2 kJ/m², Charpyimpact strength achieved by Example 2 in which anhydrous maleicacid-modified EBR was used as the compatibilizer was 10.1 kJ/m². Asignificantly improvement in impact strength was obtained. Moreover,while Charpy impact strength achieved by Comparative Example 4 in whichunmodified SEBS was used as the compatibilizer was 2.8 kJ/m², Charpyimpact strength achieved by Example 3 in which anhydrous maleicacid-modified SEBS was used as the compatibilizer was 7 kJ/m². Asignificantly improvement in impact strength was obtained.

Furthermore, clearly from the results in FIG. 2 and Table 3, it wasconfirmed that impact strength could be improved while maintainingsufficient rigidity by utilizing a modified elastomer as thecompatibilizer.

Specifically, while Charpy impact strength achieved by ComparativeExample 1 in which the modified polypropylene was used as thecompatibilizer was 1.4 kJ/m², Charpy impact strengths achieved byExamples 1 to 4 in which the modified elastomer was used as thecompatibilizer were 6.5 to 10.1 kJ/m². A significantly improvement inimpact strength was obtained.

Additionally, the result in FIG. 3 shows that the test piece of Example2 had a sea-island structure. The majority of the island phase (i.e.,polyamide resin as dispersed phase) was micro-dispersed in the sea phase(i.e., polypropylene resin as matrix phase) to have an average particlesize of about 800 nm. Therefore, it is considered that the structureobtained by utilizing the specific compatibilizer effectively improvedimpact strength and rigidity.

[1-4] Production of Thermoplastic Resin Composition (I) Using ResinOther Than PA11 as Polyamide Resin, and Making of Test Piece

Example 19

(1) Preparation of Mixed Resin

PA6 “1010X1” (nylon 6 resin, mp=225° C.) manufactured by Ube Ind., Ltd.was used as a polyamide resin (A). Anhydrous maleic acid-modified EBR“Tafmer MH7020” (MFR=1.5 g/10 min. at 230° C.) manufactured by MitsuiChemicals Inc. was used as a compatibilizer (C). Each pellet thereof wasdry-blended so as to have a mixing ratio as listed in Table 4.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=15 mm, L/D=59) manufactured by Technovel Corp.,and mixed therein under conditions of a kneading temperature at 260° C.,an extrusion speed at 2.0 kg/hr, and the number of screw revolution at200 rpm. An extruded mixed resin was then cut using a pelletizer so asto prepare a mixed resin pellet.

(2) Mixing Process

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin (B)and the previously mixed resin pellet were dry-blended so as to have amixing ratio as listed in Table 4. Subsequently, the mixture was chargedinto a twin screw kneading extruder (screw diameter=15 mm, L/D=59)manufactured by Technovel Corp., and mixed therein under conditions of akneading temperature at 260° C., an extrusion speed at 2.0 kg/hr, andthe number of screw revolution at 200 rpm. An extruded thermoplasticresin composition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Example 19.

After that, the resulting thermoplastic resin composition pellet forExample 19 was put into a hopper of an injection molding machine (40-toninjection molding machine) manufactured by Nissei Plastic Ind., Co.,Ltd., to prepare a test piece for evaluation under conditions of a settemperature at 260° C. and a mold temperature at 60° C.

Examples 20 to 24

Pellets of thermoplastic resin compositions for Examples 20 to 24 wereproduced in the same manner as that in Example 19 except thatcompatibilizers (C) shown below were used and each pellet thereof wasdry-blended so as to have a mixing ratio as listed in Table 4. Afterthat, injection molding was carried out in the same manner as that inExample 19 to prepare test pieces for Examples 20 to 24.

The compatibilizers (C) used in Examples 20 to 24 are as follows.

-   Example 20: anhydrous maleic acid-modified EBR “Tafmer MA8510”    manufactured by Mitsui Chemicals Inc. (MFR=5.0 g/10 min. at 230° C.)-   Example 21: anhydrous maleic acid-modified EBR “Tafmer MA7010”    manufactured by Mitsui Chemicals Inc. (MFR=1.8 g/10 min. at 230° C.)-   Example 22: anhydrous maleic acid-modified EBR “Tafmer MH7020”    manufactured by Mitsui Chemicals Inc. (MFR=1.5 g/10 min. at 230° C.)-   Example 23: anhydrous maleic acid-modified EBR “Tafmer MHSO40”    manufactured by Mitsui Chemicals Inc. (MFR=1.1 g/10 min. at 230° C.)-   Example 24: anhydrous maleic acid-modified EOR “AMPLIFY GR216”    manufactured by The Dow Chemical Company (Mw=150,000, maleic    anhydride content: 0.8 wt %)

Comparative Example 6

PA6 “1010X1” (nylon 6 resin, mp=225° C.) manufactured by Ube Ind., Ltd.was used as a polyamide resin (A). A polypropylene resin “Novatec MA1B”(homopolymer, Mw=312,000, mp=165° C.) manufactured by JapanPolypropylene Corp. as a polyolefin resin (B). Each resin wasdry-blended so as to have a mixing ratio as listed in Table 4.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=15 mm, L/D=59) manufactured by Technovel Corp.,and mixed therein under conditions of a kneading temperature at 260° C.,an extrusion speed at 2.0 kg/hr, and the number of screw revolution at200 rpm. An extruded thermoplastic resin composition was then cut usinga pelletizer so as to prepare a thermoplastic resin composition pelletfor Comparative Example 6.

After that, the resulting thermoplastic resin composition pellet forComparative Example 6 was put into a hopper of an injection moldingmachine (40-ton injection molding machine) manufactured by NisseiPlastic Ind., Co., Ltd., to prepare a test piece for evaluation underconditions of a set temperature at 260° C. and a mold temperature at 60°C.

Example 25

(1) Preparation of Mixed Resin

PA12 “Rilsan AECN OTL” (nylon 12 resin, mp=174-178° C.) manufactured byARKEMA K.K. was used as a polyamide resin (A). Anhydrous maleicacid-modified EBR “Tafmer MH7020” (MFR=1.5 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C).Each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 5. Subsequently, the mixture was charged into a twinscrew kneading extruder (screw diameter=15 mm, L/D=59) manufactured byTechnovel Corp., and mixed therein under conditions of a kneadingtemperature at 210° C., an extrusion speed at 2.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded mixed resin was then cutusing a pelletizer so as to prepare a mixed resin pellet.

(2) Mixing Process

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin (B)and the previously mixed resin pellet were dry-blended so as to have amixing ratio as listed in Table 5. Subsequently, the mixture was chargedinto a twin screw kneading extruder (screw diameter-15 mm, L/D=59)manufactured by Technovel Corp., and mixed therein under conditions of akneading temperature at 210° C., an extrusion speed at 2.0 kg/hr, andthe number of screw revolution at 200 rpm. An extruded thermoplasticresin composition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Example 25.

After that, the resulting thermoplastic resin composition pellet forExample 25 was put into a hopper of an injection molding machine (40-toninjection molding machine) manufactured by Nissei Plastic Ind., Co.,Ltd., to prepare a test piece for evaluation under conditions of a settemperature at 210° C. and a mold temperature at 60° C.

Example 26

A pellet of a thermoplastic resin composition for Example 26 wasproduced in the same manner as that in Example 25 except that eachpellet was dry-blended so as to have a mixing ratio as listed in Table5. Then, injection molding was carried out in the same manner as that inExample 25 to prepare a test piece for Example 26.

Comparative Example 7

PA12 “Rilsan AECN OTL” (nylon 12 resin, mp=174-178° C.) manufactured byARKEMA K.K. as a polyamide resin (A) was charged into a twin screwkneading extruder (screw diameter=15 mm, L/D=59) manufactured byTechnovel Corp., and mixed therein under conditions of a kneadingtemperature at 210° C., an extrusion speed at 2.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded thermoplastic resincomposition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Comparative Example 7 (seeTable 5). Then, injection molding was carried out in the same manner asthat in Example 25 to prepare a test piece for Comparative Example 7.

Example 27

(1) Preparation of Mixed Resin

PA610 “Vestamid Terra HS16” (nylon 610 resin, mp=222° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). Anhydrousmaleic acid-modified EBR “Tafmer MH7020” (MFR=1.5 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C).Each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 6. Subsequently, the mixture was charged into a twinscrew kneading extruder (screw diameter=25 mm, L/D=41) manufactured byParker Corp., Inc. and mixed therein under conditions of a kneadingtemperature at 235° C., an extrusion speed at 3.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded mixed resin was then cutusing a pelletizer so as to prepare a mixed resin pellet.

(2) Mixing Process

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin (B)and the previously mixed resin pellet were dry-blended so as to have amixing ratio as listed in Table 6. Subsequently, the mixture was chargedinto a twin screw kneading extruder (screw diameter=25 mm, L/D=41)manufactured by Parker Corp., Inc. and mixed therein under conditions ofa kneading temperature at 235° C., an extrusion speed at 3.0 kg/hr, andthe number of screw revolution at 200 rpm. An extruded thermoplasticresin composition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Example 27.

After that, the resulting thermoplastic resin composition pellet forExample 27 was put into a hopper of an injection molding machine (40-toninjection molding machine) manufactured by Nissei Plastic Ind., Co.,Ltd., to prepare a test piece for evaluation under conditions of a settemperature at 235° C. and a mold temperature at 60° C.

Examples 28 to 32

Pellets of thermoplastic resin compositions for Examples 28 to 32 wereproduced in the same manner as that in Example 27 except that eachpellet was dry-blended so as to have a mixing ratio as listed in Table6. Then, injection molding was carried out in the same manner as that inExample 27 to prepare test pieces for Example 28 to 32.

Comparative Example 8

PA610 “Vestamid Terra HS16” (nylon 610 resin, mp=222° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). A polypropyleneresin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165° C.) manufacturedby Japan Polypropylene Corp. as a polyolefin resin (B). Each resin wasdry-blended so as to have a mixing ratio as listed in Table 6.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at235° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded thermoplastic resin composition wasthen cut using a pelletizer so as to prepare a thermoplastic resincomposition pellet for Comparative Example 8.

After that, the resulting thermoplastic resin composition pellet forComparative Example 8 was put into a hopper of an injection moldingmachine (40-ton injection molding machine) manufactured by NisseiPlastic Ind., Co., Ltd., to prepare a test piece for evaluation underconditions of a set temperature at 235° C. and a mold temperature at 60°C.

Example 33

(1) Preparation of Mixed Resin

PA1010 “Vestamid Terra DS16” (nylon 1010 resin, mp=206° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). Anhydrousmaleic acid-modified EBR “Tafmer MH7020” (MFR=1.5 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C).Each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 7. Subsequently, the mixture was charged into a twinscrew kneading extruder (screw diameter=25 mm, L/D=41) manufactured byParker Corp., Inc. and mixed therein under conditions of a kneadingtemperature at 250° C., an extrusion speed at 3.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded mixed resin was then cutusing a pelletizer so as to prepare a mixed resin pellet.

(2) Mixing Process

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin (B)and the previously mixed resin pellet were dry-blended so as to have amixing ratio as listed in Table 7. Subsequently, the mixture was chargedinto a twin screw kneading extruder (screw diameter=25 mm, L/D=41)manufactured by Parker Corp., Inc. and mixed therein under conditions ofa kneading temperature at 250° C., an extrusion speed at 3.0 kg/hr, andthe number of screw revolution at 200 rpm. An extruded thermoplasticresin composition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Example 33.

After that, the resulting thermoplastic resin composition pellet forExample 33 was put into a hopper of an injection molding machine (40-toninjection molding machine) manufactured by Nissei Plastic Ind., Co.,Ltd., to prepare a test piece for evaluation under conditions of a settemperature at 250° C. and a mold temperature at 60° C.

Examples 34 to 38

Pellets of thermoplastic resin compositions for Examples 34 to 38 wereproduced in the same manner as that in Example 33 except that eachpellet was dry-blended so as to have a mixing ratio as listed in Table7. Then, injection molding was carried out in the same manner as that inExample 33 to prepare test pieces for Example 34 to 38.

Comparative Example 9

PA1010 “Vestamid Terra DS16” (nylon 1010 resin, mp=206° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). A polypropyleneresin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165° C.) manufacturedby Japan Polypropylene Corp. as a polyolefin resin (B). Each resin wasdry-blended so as to have a mixing ratio as listed in Table 7.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at250° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded thermoplastic resin composition wasthen cut using a pelletizer so as to prepare a thermoplastic resincomposition pellet for Comparative Example 9.

After that, the resulting thermoplastic resin composition pellet forComparative Example 9 was put into a hopper of an injection moldingmachine (40-ton injection molding machine) manufactured by NisseiPlastic Ind., Co., Ltd., to prepare a test piece for evaluation underconditions of a set temperature at 250° C. and a mold temperature at 60°C.

Example 39

(1) Preparation of Mixed Resin

PAMXD6 “Reny 6002” (nylon MXD6 resin, mp=243° C.) manufactured byMitsubishi Engineering-Plastics Corp. was used as a polyamide resin (A).Anhydrous maleic acid-modified EBR “Tafmer MH7020” (MFR=1.5 g/10 min. at230° C.) manufactured by Mitsui Chemicals Inc. was used as acompatibilizer (C). Each pellet thereof was dry-blended so as to have amixing ratio as listed in Table 8. Subsequently, the mixture was chargedinto a twin screw kneading extruder (screw diameter=25 mm, L/D=41)manufactured by Parker Corp., Inc. and mixed therein under conditions ofa kneading temperature at 265° C., an extrusion speed at 3.0 kg/hr, andthe number of screw revolution at 200 rpm. An extruded mixed resin wasthen cut using a pelletizer so as to prepare a mixed resin pellet.

(2) Mixing Process

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin (B)and the previously mixed resin pellet were dry-blended so as to have amixing ratio as listed in Table 8. Subsequently, the mixture was chargedinto a twin screw kneading extruder (screw diameter=25 mm, L/D=41)manufactured by Parker Corp., Inc. and mixed therein under conditions ofa kneading temperature at 265° C., an extrusion speed at 3.0 kg/hr, andthe number of screw revolution at 200 rpm. An extruded thermoplasticresin composition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Example 39.

After that, the resulting thermoplastic resin composition pellet forExample 39 was put into a hopper of an injection molding machine (40-toninjection molding machine) manufactured by Nissei Plastic Ind., Co.,Ltd., to prepare a test piece for evaluation under conditions of a settemperature at 265° C. and a mold temperature at 90° C.

Examples 40 to 44

Pellets of thermoplastic resin compositions for Examples 40 to 44 wereproduced in the same manner as that in Example 39 except that eachpellet was dry-blended so as to have a mixing ratio as listed in Table8. Then, injection molding was carried out in the same manner as that inExample 39 to prepare test pieces for Example 40 to 44.

Comparative Example 10

PAMXD6 “Reny 6002” (nylon MXD6 resin, mp=243° C.) manufactured byMitsubishi Engineering-Plastics Corp. was used as a polyamide resin (A).A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin (B).Each resin was dry-blended so as to have a mixing ratio as listed inTable 8. Subsequently, the mixture was charged into a twin screwkneading extruder (screw diameter=25 mm, L/D=41) manufactured by ParkerCorp., Inc., and mixed therein under conditions of a kneadingtemperature at 265° C., an extrusion speed at 3.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded thermoplastic resincomposition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Comparative Example 10.

After that, the resulting thermoplastic resin composition pellet forComparative Example 10 was put into a hopper of an injection moldingmachine (40-ton injection molding machine) manufactured by NisseiPlastic Ind., Co., Ltd., to prepare a test piece for evaluation underconditions of a set temperature at 265° C. and a mold temperature at 90°C.

Example 45

(1) Preparation of Mixed Resin

PA10T “Vestamid HT Plus M300” (nylon 10T resin, mp=285° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). Anhydrousmaleic acid-modified EBR “Tafmer MH7020” (MFR=1.5 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C).Each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 9. Subsequently, the mixture was charged into a twinscrew kneading extruder (screw diameter=25 mm, L/D=41) manufactured byParker Corp., Inc. and mixed therein under conditions of a kneadingtemperature at 310° C., an extrusion speed at 3.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded mixed resin was then cutusing a pelletizer so as to prepare a mixed resin pellet.

(2) Mixing Process

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. as a polyolefin resin (B)and the previously mixed resin pellet were dry-blended so as to have amixing ratio as listed in Table 9. Subsequently, the mixture was chargedinto a twin screw kneading extruder (screw diameter=25 mm, L/D=41)manufactured by Parker Corp., Inc. and mixed therein under conditions ofa kneading temperature at 310° C., an extrusion speed at 3.0 kg/hr, andthe number of screw revolution at 200 rpm. An extruded thermoplasticresin composition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet for Example 45.

After that, the resulting thermoplastic resin composition pellet forExample 45 was put into a hopper of an injection molding machine (40-toninjection molding machine) manufactured by Nissei Plastic Ind., Co.,Ltd., to prepare a test piece for evaluation under conditions of a settemperature at 310° C. and a mold temperature at 90° C.

Examples 46 and 47

Pellets of thermoplastic resin compositions for Examples 46 and 47 wereproduced in the same manner as that in Example 45 except that eachpellet was dry-blended so as to have a mixing ratio as listed in Table9. Then, injection molding was carried out in the same manner as that inExample 45 to prepare test pieces for Example 46 and 47.

Comparative Example 11

PA10T “Vestamid HT Plus M300” (nylon 10T resin, mp=285° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). A polypropyleneresin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165° C.) manufacturedby Japan Polypropylene Corp. as a polyolefin resin (B). Each resin wasdry-blended so as to have a mixing ratio as listed in Table 9.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at310° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded thermoplastic resin composition wasthen cut using a pelletizer so as to prepare a thermoplastic resincomposition pellet for Comparative Example 11.

After that, the resulting thermoplastic resin composition pellet forComparative Example 11 was put into a hopper of an injection moldingmachine (40-ton injection molding machine) manufactured by NisseiPlastic Ind., Co., Ltd., to prepare a test piece for evaluation underconditions of a set temperature at 310° C. and a mold temperature at 90°C.

TABLE 4 Comparative Example Example 19 20 21 22 23 24 6 Mixing (A)Polyamide (PA6) 25 60 60 60 60 60 67 ratio (B) Polyolefin 65 30 30 30 3030 33 (% by (C) Compati- Anhydrous maleic — 10 — — — — — mass) bilizeracid-modified EBR (“Tafmer MA8510”) Anhydrous maleic — — 10 — — — —acid-modified EBR (“Tafmer MH7010”) Anhydrous maleic 10 — — 10 — — —acid-modified EBR (“Tafmer MH7020”) Anhydrous maleic — — — — 10 — —acid-modified EBR (“Tafmer MH504CT) Anhydrous maleic — — — — — 10 —acid-modified EOR Charpy impact strength (kJ/m²) 8.5 3.9 5.2 11.9 16.67.3 2.3 Flexural modulus (MPa) 1401 1467 1449 1401 1325 1392 2022

TABLE 5 Comparative Example Example 25 26 7 Mixing (A) Polyamide (PA12)25 30 100 ratio (B) Polyolefin 65 60 — (% by (C) Compatibilizer 10 10 —mass) (Anhydrous maleic acid-modified EBR “Tafmer MH7020”) Charpy impactstrength (kJ/m²) 7.7 12.8 2.8 Flexural modulus (MPa) 1434 1253 1340

TABLE 6 Comparative Example Example 27 28 29 30 31 32 8 Mixing (A)Polyamide (PA610) 25 25 25 40 55 70 28 ratio (B) Polyolefin 65 55 45 5035 20 72 (% by (C) Compatibilizer 10 20 30 10 10 10 — mass) (Anhydrousmaleic acid-modified EBR “Tafmer MH7020”) Charpy impact strength (kJ/m²)5.4 14.0 40.0 8.6 9.1 8.3 2.1 Flexural modulus (MPa) 1390 930 660 13701360 1380 1730

TABLE 7 Comparative Example Example 33 34 35 36 37 38 9 Mixing (A)Polyamide (PA1010) 25 25 25 40 55 70 28 ratio (B) Polyolefin 65 55 45 5035 20 72 (% by (C) Compatibilizer 10 20 30 10 10 10 — mass) (Anhydrousmaleic acid-modified EBR “Tafmer MH7020”) Charpy impact strength (kJ/m²)3.0 15.4 40.0 2.1 4.8 8.1 1.1 Flexural modulus (MPa) 1230 880 550 13501340 1320 1650

TABLE 8 Comparative Example Example 39 40 41 42 43 44 10 Mixing (A)Polyamide (PAMXD6) 25 25 25 40 55 70 28 ratio (B) Polyolefin 65 55 45 5035 20 72 (% by (C) Compatibilizer 10 20 30 10 10 10 — mass) (Anhydrousmaleic acid-modified EBR “Tafmer MH7020”) Charpy impact strength (kJ/m²)3.0 13.6 56.0 2.2 2.6 4.9 1.1 Flexural modulus (MPa) 1650 1010 820 19302290 2640 2270

TABLE 9 Comparative Example Example 45 46 47 11 Mixing (A) Polyamide 2545 60 28 ratio (PA10T) (% by (B) Polyolefin 55 45 30 72 mass) (C)Compatibilizer 20 10 10 — (Anhydrous maleic acid-modified EBR “TafmerMH7020”) Charpy impact strength (kJ/m²) 5.0 2.1 3.8 1.1 Flexural modulus(MPa) 910 1590 1620 1860[1-5] Evaluation of Thermoplastic Resin Composition (I) (Examples 19 to47 and Comparative Examples 6 to 11)

Test pieces for evaluation obtained in Examples 19 to 47 and ComparativeExamples 6 to 11 of the above section [1-4] were subjected tomeasurement for Charpy impact strength and flexural modulus according tothe same method as the above section [1-2]. Results thereof were shownin Tables 4 to 9.

[1-6] Effects of Examples 19 to 47

According to the results in Table 4, Comparative Example 6 in which PA6was used as the polyamide and the compatibilizer was not used hadflexural modulus of 2,022 MPa, but Charpy impact strength was as low as2.3 kJ/m².

On the other hand, Examples 19 to 24 in which PA6 was used as thepolyamide and the modified elastomer was used as the compatibilizer hadflexural moduli of 1,325 to 1,467 MPa, and Charpy impact strengths of3.9 to 16.6 kJ/m². It was found that Examples 19 to 24 were excellent inimpact strength as well as rigidity.

According to the results in Table 5, Comparative Example 7 in which PA12was used as the polyamide and the polyolefin and the compatibilizer werenot used had flexural modulus of 1,340 MPa, but Charpy impact strengthwas as low as 2.8 kJ/m².

On the other hand, Examples 25 and 26 in which PA12 was used as thepolyamide and the modified elastomer was used as the compatibilizer hadflexural moduli of 1,253 to 1,434 MPa, and Charpy impact strengths of7.7 to 12.8 kJ/m². It was found that Examples 25 and 26 were excellentin impact strength as well as rigidity.

According to the results in Table 6, Comparative Example 8 in whichPA610 was used as the polyamide and the compatibilizer was not used hadflexural modulus of 1,730 MPa, but Charpy impact strength was as low as2.1 kJ/m².

On the other hand, Examples 27 to 32 in which PA610 was used as thepolyamide and the modified elastomer was used as the compatibilizer hadflexural moduli of 660 to 1,390 MPa, and Charpy impact strengths of 5.4to 40.0 kJ/m². It was found that Examples 27 to 32 were excellent inimpact strength as well as rigidity.

According to the results in Table 7, Comparative Example 9 in whichPA1010 was used as the polyamide and the compatibilizer was not used hadflexural modulus of 1,650 MPa, but Charpy impact strength was as low as1.1 kJ/m².

On the other hand, Examples 33 to 38 in which PA1010 was used as thepolyamide, and the modified elastomer was used as the compatibilizer hadflexural moduli of 550 to 1,350 MPa, and Charpy impact strengths of 2.1to 40.0 kJ/m². It was found that Examples 33 to 38 were excellent inimpact strength as well as rigidity.

According to the results in Table 8, Comparative Example 10 in whichPAMXD6 was used as the polyamide and the compatibilizer was not used hadflexural modulus of 2,270 MPa, but Charpy impact strength was as low as1.1 kJ/m².

On the other hand, Examples 39 to 44 in which PAMXD6 was used as thepolyamide and the modified elastomer was used as the compatibilizer hadflexural moduli of 820 to 2,640 MPa, and Charpy impact strengths of 2.2to 56.0 kJ/m². It was found that Examples 39 to 44 were excellent inimpact strength as well as rigidity.

According to the results in Table 9, Comparative Example 11 in whichPA10T was used as the polyamide and the compatibilizer was not used hadflexural modulus of 1,860 MPa, but Charpy impact strength was low as lowas 1.1 kJ/m².

On the other hand, Examples 45 to 47 in which PA10T was used as thepolyamide and the modified elastomer was used as the compatibilizer hadflexural moduli of 910 to 1,620 MPa, and Charpy impact strengths of 2.1to 5.0 kJ/m². It was found that Examples 45 to 47 were excellent inimpact strength as well as rigidity.

[2-1] Production of Thermoplastic Resin Composition (II) Using PA11 asPolyamide Resin, and Making of Test Piece

Experimental Examples 1 to 18 (Inventive Product)

PA11 “Rilsan BMN O” (nylon 11 resin, Mw=18,000) manufactured by ARKEMAK.K. was used as a polyamide resin (A). Anhydrous maleic acid-modifiedethylene butene copolymer (c1) (modified EBR) “Tafmer MH7020” (MFR=1.5g/10 min. at 230° C.) manufactured by Mitsui Chemicals Inc. was used asa compatibilizer (C). Each pellet thereof was dry-blended so as to havea mixing ratio as listed in Table 10 or Table 11. Subsequently, themixture was charged into a twin screw kneading extruder (screwdiameter=15 mm, L/D=59) manufactured by Technovel Corp., and mixedtherein under conditions of a kneading temperature at 210° C., anextrusion speed at 2.0 kg/hr, and the number of screw revolution at 200rpm. An extruded mixed resin was then cut using a pelletizer so as toprepare a mixed resin of polyamide resin (A) and compatibilizer (C).

The resulting mixed resin and a polypropylene resin “Novatec MA1B”(homopolymer, Mw=312,000, mp=165° C.) manufactured by JapanPolypropylene Corp. as a polyolefin resin (B) were dry-blended so as tohave a mixing ratio as listed in Table 10 or Table 11. Subsequently, themixture was charged into a twin screw kneading extruder (screwdiameter=15 mm, L/D=59) manufactured by Technovel Corp., and mixedtherein under conditions of a kneading temperature at 210° C., anextrusion speed at 2.0 kg/hr, and the number of screw revolution at 200rpm. An extruded composition was then cut using a pelletizer so as toprepare a thermoplastic resin composition pellet containing aplant-derived polyamide resin for Experimental Examples 1 to 18.

After that, the resulting composition pellet for Experimental Examples 1to 18 was put into a hopper of an injection molding machine (40-toninjection molding machine) manufactured by Nissei Plastic Ind., Co.,Ltd., to prepare a test piece of a thermoplastic resin compositionpellet containing a plant-derived polyamide resin for ExperimentalExamples 1 to 18 for evaluation under conditions of a set temperature at210° C. and a mold temperature at 60° C.

Experimental Example 19 (Inventive Product)

A pellet of thermoplastic resin composition containing a plant-derivedpolyamide resin for Experimental Example 19 was produced in the samemanner as that in Experimental Examples 1 to 18 except that anhydrousmaleic acid-modified propylene butene copolymer (c2) (modified EPR)“Tafmer MP0620” (MFR=0.3 g/10 min. at 230° C.) manufactured by MitsuiChemicals Inc. was used as a compatibilizer (C). After that, a testpiece of a thermoplastic resin composition containing a plant-derivedpolyamide resin for Experimental Example 19 was prepared in the samemanner as that in Experimental Examples 1 to 18.

Experimental Example 20 (Inventive Product)

A polypropylene resin “Novatec MA1B” (homopolymer, Mw=312,000, mp=165°C.) manufactured by Japan Polypropylene Corp. was used as a polyolefinresin (B). Anhydrous maleic acid-modified propylene butene copolymer(c2) (modified EPR) “Tafmer MP0620” (MFR=0.3 g/10 min. at 230° C.)manufactured by Mitsui Chemicals Inc. was used as a compatibilizer (C).Each pellet thereof was dry-blended so as to have a mixing ratio aslisted in Table 11. Subsequently, the mixture was charged into a twinscrew kneading extruder (screw diameter=15 mm, L/D=59) manufactured byTechnovel Corp., and mixed therein under conditions of a kneadingtemperature at 210° C., an extrusion speed at 2.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded mixed resin was then cutusing a pelletizer so as to prepare a mixed resin of polyolefin resin(B) and compatibilizer (C).

The resulting mixed resin and PA11 “Rilsan BMN O” (nylon 11 resin,Mw=18,000) manufactured by ARKEMA K.K. as a polyamide resin (A) weredry-blended so as to have a mixing ratio as listed in Table 11.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=15 mm, L/D=59) manufactured by Technovel Corp.,and mixed therein under conditions of a kneading temperature at 210° C.,an extrusion speed at 2.0 kg/hr, and the number of screw revolution at200 rpm. An extruded composition was then cut using a pelletizer so asto prepare a thermoplastic resin composition pellet containing aplant-derived polyamide resin for Experimental Example 20.

After that, the resulting composition pellet for Experimental Example 20was put into a hopper of an injection molding machine (40-ton injectionmolding machine) manufactured by Nissei Plastic Ind., Co., Ltd., toprepare a test piece of a thermoplastic resin composition pelletcontaining a plant-derived polyamide resin for Experimental Example 20for evaluation under conditions of a set temperature at 210° C. and amold temperature at 60° C.

Experimental Example 21 (Inventive Product)

A pellet of thermoplastic resin composition containing a plant-derivedpolyamide resin for Experimental Example 21 was produced in the samemanner as that in Experimental Examples 1 to 18 except that anhydrousmaleic acid-modified ethylene octene copolymer (c3) (modified EOR)“AMPLIFY GR216” (Mw=150,000, anhydrous maleic acid-modified content: 0.8wt %) manufactured by The Dow Chemical Company was used as acompatibilizer (C). After that, a test piece of a thermoplastic resincomposition containing a plant-derived polyamide resin for ExperimentalExample 21 was prepared in the same manner as that in ExperimentalExamples 1 to 18.

TABLE 10 Experimental Example 1 2 3 4 5 6 7 8 9 10 11 Mixing (A)Polyamide PA11 1 5 10 20 25 30 40 50 60 70 80 ratio (B) Polyolefin PP 8985 80 70 65 60 50 40 30 20 10 (% by (C) Compati- (c1) Modified 10 10 1010 10 10 10 10 10 10 10 mass) bilizer EBR (c2) Modified — — — — — — — —— — — EPR Mixing (B) was used after ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ method mixing(A) and (C) (A) was used after — — — — — — — — — — — mixing (B) and (C)Prop- Charpy impact strength (kJ/m²) 3.7 6.6 8.0 10.1 8.8 9.5 10.3 18.262.0 25.6 72.1 erties Flexural modulus (MPa) 1105 1078 1046 1241 11841182 1148 1062 946 927 866 Specific gravity 0.90 0.90 0.91 0.92 0.930.94 0.95 0.96 0.98 0.99 1.00

TABLE 11 Experimental Example 12 9 13 14 15 16 17 18 19 20 21 Mixing (A)Polyamide PA11 60 60 60 60 25 25 25 25 20 20 20 ratio (B) Polyolefin PP35 30 25 20 70 60 55 45 70 70 70 (% by (C) Compati- (c1) Modified 5 1015 20 5 15 20 30 — — — mass) bilizer EBR (c2) Modified — — — — — — — —10 10 — EPR (c3) Modified — — — — — — — — — — 10 EOR Mixing (B) was usedafter ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ — ◯ method mixing (A) and (C) (A) was used after— — — — — — — — — ◯ — mixing (B) and (C) Prop- Charpy impact strength(kJ/m²) 6.4 62.0 80.0 86.3 3.8 17.9 72.9 69.4 6.5 5.9 9.18 ertiesFlexural modulus (MPa) 1211 946 852 710 1275 952 775 453 1238 1114 1117Specific gravity 0.98 0.98 0.97 0.97 0.93 0.93 0.93 0.92 0.92 0.92 0.92[2-2] Evaluation of Thermoplastic Resin Composition (II)(1) Measurement of Charpy Impact Strength

Test pieces for evaluation obtained in Experimental Examples 1 to 21 ofthe above section [2-1] were subjected to measurement in accordance withHS K7111-1 for Charpy impact strength. Results thereof were shown inTables 10 and 11. In the measurement of Charpy impact strength, theimpact was measured by an edgewise test method at a temperature of 23°C. with a test piece having notch (type A).

(2) Measurement of Flexural Modulus

Test pieces for evaluation obtained in Experimental Examples 1 to 21 ofthe above section [2-1] were subjected to measurement in accordance withJIS K7171 for flexural modulus. Results thereof were shown in Tables 10and 11. The flexural modulus was measured by supporting each of testpieces at two points (radius of curvature: 5 mm) with a distance L of 64mm therebetween while applying a load at a speed of 2 mm/min from anaction point (radius of curvature: 5 mm) positioned in the middle of thetwo points.

[2-3] Measurement Results

Clearly from the results in Tables 10 and 11, Experimental Examples 1 to21 had flexural moduli of 453 to 1,275 MPa, and Charpy impact strengthsof 3.7 to 86.3 kJ/m². It was found that Experimental Examples 1 to 21were excellent in impact strength as well as rigidity.

[2-4] Production of Thermoplastic Resin Composition Using Resin Otherthan PA11 as Polyamide Resin, and Making of Test Piece

Experimental Example 22 (Inventive Product)

PA610 “Vestamid Terra HS16” (nylon 610 resin, mp=222° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). Anhydrousmaleic acid-modified ethylene butene copolymer (modified EBR) “TafmerMH7020” (MFR=1.5 g/10 min. at 230° C.) manufactured by Mitsui ChemicalsInc. was used as a compatibilizer (C). Each pellet thereof wasdry-blended so as to have a mixing ratio as listed in Table 12.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at235° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded composition was then cut using apelletizer so as to prepare a mixed resin pellet of polyamide resin (A)and compatibilizer (C).

The resulting mixed resin and a polypropylene resin “Novatec MA1B”(homopolymer, Mw=312,000, mp=165° C.) manufactured by JapanPolypropylene Corp. as a polyolefin resin (B) were dry-blended so as tohave a mixing ratio as listed in Table 12. Subsequently, the mixture wascharged into a twin screw kneading extruder (screw diameter=25 mm,L/D=41) manufactured by Parker Corp., Inc., and mixed therein underconditions of a kneading temperature at 235° C., an extrusion speed at3.0 kg/hr, and the number of screw revolution at 200 rpm. An extrudedcomposition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet containing a plant-derivedpolyamide resin for Experimental Example 22.

After that, the resulting composition pellet for Experimental Example 22was put into a hopper of an injection molding machine (40-ton injectionmolding machine) manufactured by Nissei Plastic Ind., Co., Ltd., toprepare a test piece of a thermoplastic resin composition pelletcontaining a plant-derived polyamide resin for Experimental Example 22for evaluation under conditions of a set temperature at 235° C. and amold temperature at 60° C.

Experimental Examples 23 to 27 (Inventive Product)

Pellets of thermoplastic resin compositions for Experimental Examples 23to 27 were produced in the same manner as that in Experimental Example22 except that each pellet was dry-blended so as to have a mixing ratioas listed in Table 12. Then, injection molding was carried out in thesame manner as that in Experimental Example 22 to prepare test piecesfor Experimental Examples 23 to 27.

Experimental Example 28 (Comparative Product)

PA610 “Vestamid Terra HS16” (nylon 610 resin, mp=222° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). A polypropyleneresin “Novatec MA1B” (homopolymer, Mw=312,000) manufactured by JapanPolypropylene Corp. as a polyolefin resin (B). Each resin wasdry-blended so as to have a mixing ratio as listed in Table 12.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at235° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded thermoplastic resin composition wasthen cut using a pelletizer so as to prepare a thermoplastic resincomposition pellet containing a plant-derived polyamide resin forExperimental Example 28.

After that, the resulting composition pellet for Experimental Example 28was put into a hopper of an injection molding machine (40-ton injectionmolding machine) manufactured by Nissei Plastic Ind., Co., Ltd., toprepare a test piece for evaluation under conditions of a settemperature at 235° C. and a mold temperature at 60° C.

Experimental Example 29 (Inventive Product)

PA1010 “Vestamid Terra DS16” (nylon 1010 resin, mp=206° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). Anhydrousmaleic acid-modified ethylene butene copolymer (modified EBR) “TafmerMH7020” (MFR=1.5 g/10 min. at 230° C.) manufactured by Mitsui ChemicalsInc. was used as a compatibilizer (C). Each pellet thereof wasdry-blended so as to have a mixing ratio as listed in Table 13.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at250° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded composition was then cut using apelletizer so as to prepare a mixed resin pellet of polyamide resin (A)and compatibilizer (C).

The resulting mixed resin and a polypropylene resin “Novatec MA1B”(homopolymer, Mw=312,000, mp=165° C.) manufactured by JapanPolypropylene Corp. as a polyolefin resin (B) were dry-blended so as tohave a mixing ratio as listed in Table 13. Subsequently, the mixture wascharged into a twin screw kneading extruder (screw diameter=25 mm,L/D=41) manufactured by Parker Corp., Inc., and mixed therein underconditions of a kneading temperature at 250° C., an extrusion speed at3.0 kg/hr, and the number of screw revolution at 200 rpm. An extrudedcomposition was then cut using a pelletizer so as to prepare athermoplastic resin composition pellet containing a plant-derivedpolyamide resin for Experimental Example 29.

After that, the resulting composition pellet for Experimental Example 29was put into a hopper of an injection molding machine (40-ton injectionmolding machine) manufactured by Nissei Plastic Ind., Co., Ltd., toprepare a test piece of a thermoplastic resin composition pelletcontaining a plant-derived polyamide resin for Experimental Example 29for evaluation under conditions of a set temperature at 250° C. and amold temperature at 60° C.

Experimental Examples 30 to 34 (Inventive Product)

Pellets of thermoplastic resin compositions for Experimental Examples 30to 34 were produced in the same manner as that in Experimental Example29 except that each pellet was dry-blended so as to have a mixing ratioas listed in Table 13. Then, injection molding was carried out in thesame manner as that in Experimental Example 29 to prepare test piecesfor Experimental Examples 30 to 34.

Experimental Example 35 (Comparative Product)

PA1010 “Vestamid Terra DS16” (nylon 1010 resin, mp=206° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). A polypropyleneresin “Novatec MA1B” (homopolymer, Mw=312,000) manufactured by JapanPolypropylene Corp. as a polyolefin resin (B). Each resin wasdry-blended so as to have a mixing ratio as listed in Table 13.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at250° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded thermoplastic resin composition wasthen cut using a pelletizer so as to prepare a thermoplastic resincomposition pellet containing a plant-derived polyamide resin forExperimental Example 35.

After that, the resulting composition pellet for Experimental Example 35was put into a hopper of an injection molding machine (40-ton injectionmolding machine) manufactured by Nissei Plastic Ind., Co., Ltd., toprepare a test piece for evaluation under conditions of a settemperature at 250° C. and a mold temperature at 60° C.

Experimental Example 36 (Inventive Product)

PA10T “Vestamid HT Plus M300” (nylon 10T resin, mp=285° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). Anhydrousmaleic acid-modified ethylene butene copolymer (modified EBR) “TafmerMH7020” (MFR=1.5 g/10 min. at 230° C.) manufactured by Mitsui ChemicalsInc. was used as a compatibilizer (C). Each pellet thereof wasdry-blended so as to have a mixing ratio as listed in Table 14.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at310° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded composition was then cut using apelletizer so as to prepare a mixed resin pellet of polyamide resin (A)and compatibilizer (C).

The resulting mixed resin and a polypropylene resin “Novatec MA1B”(homopolymer, Mw=312,000) manufactured by Japan Polypropylene Corp. as apolyolefin resin (B) were dry-blended so as to have a mixing ratio aslisted in Table 14. Subsequently, the mixture was charged into a twinscrew kneading extruder (screw diameter=25 mm, L/D=41) manufactured byParker Corp., Inc., and mixed therein under conditions of a kneadingtemperature at 310° C., an extrusion speed at 3.0 kg/hr, and the numberof screw revolution at 200 rpm. An extruded composition was then cutusing a pelletizer so as to prepare a thermoplastic resin compositionpellet containing a plant-derived polyamide resin for ExperimentalExample 36.

After that, the resulting composition pellet for Experimental Example 36was put into a hopper of an injection molding machine (40-ton injectionmolding machine) manufactured by Nissei Plastic Ind., Co., Ltd., toprepare a test piece of a thermoplastic resin composition pelletcontaining a plant-derived polyamide resin for Experimental Example 36for evaluation under conditions of a set temperature at 310° C. and amold temperature at 90° C.

Experimental Examples 37 and 38 (Inventive Product)

Pellets of thermoplastic resin compositions for Experimental Examples 37and 38 were produced in the same manner as that in Experimental Example36 except that each pellet was dry-blended so as to have a mixing ratioas listed in Table 14. Then, injection molding was carried out in thesame manner as that in Experimental Example 36 to prepare test piecesfor Experimental Examples 37 and 38.

Experimental Example 39 (Comparative Product)

PA10T “Vestamid HT Plus M300” (nylon 10T resin, mp=285° C.) manufacturedby Daicel-Evonik Ltd. was used as a polyamide resin (A). A polypropyleneresin “Novatec MA1B” (homopolymer, Mw=312,000) manufactured by JapanPolypropylene Corp. as a polyolefin resin (B). Each resin wasdry-blended so as to have a mixing ratio as listed in Table 14.Subsequently, the mixture was charged into a twin screw kneadingextruder (screw diameter=25 mm, L/D=41) manufactured by Parker Corp.,Inc., and mixed therein under conditions of a kneading temperature at310° C., an extrusion speed at 3.0 kg/hr, and the number of screwrevolution at 200 rpm. An extruded thermoplastic resin composition wasthen cut using a pelletizer so as to prepare a thermoplastic resincomposition pellet containing a plant-derived polyamide resin forExperimental Example 39.

After that, the resulting thermoplastic resin composition pellet forExperimental Example 39 was put into a hopper of an injection moldingmachine (40-ton injection molding machine) manufactured by NisseiPlastic Ind., Co., Ltd., to prepare a test piece for evaluation underconditions of a set temperature at 310° C. and a mold temperature at 90°C.

TABLE 12 Experimental Example 22 23 24 25 26 27 28 Mixing (A) Polyamide(PA610) 25 25 25 40 55 70 28 ratio (B) Polyolefin 65 55 45 50 35 20 72(% by (C) Compatibilizer 10 20 30 10 10 10 — mass) (Anhydrous maleicacid-modified EBR “Tafmer MH7020”) Mixing (B) was used after ◯ ◯ ◯ ◯ ◯ ◯— method mixing (A) and (C) (A) and (B) were mixed — — — — — — ◯ Prop-Charpy impact 5.4 14 40.0 8.6 9.1 8.3 2.1 erties strength (kJ/m²)Flexural modulus (MPa) 1390 930 660 1370 1360 1380 1730 Specific gravity0.942 0.942 0.936 0.969 0.996 1.023 0.855

TABLE 13 Experimental Example 29 30 31 32 33 34 35 Mixing (A) Polyamide(PA1010) 25 25 25 40 55 70 28 ratio (B) Polyolefin 65 55 45 50 35 20 72(% by (C) Compatibilizer 10 20 30 10 10 10 — mass) (Anhydrous maleicacid-modified EBR “Tafmer MH7020”) Mixing (B) was used after ◯ ◯ ◯ ◯ ◯ ◯— method mixing (A) and (C) (A) and (B) were mixed — — — — — — ◯ Prop-Charpy impact 3.0 15.4 40.0 2.1 4.8 8.1 1.1 erties strength (kJ/m²)Flexural modulus (MPa) 1230 880 550 1350 1340 1320 1650 Specific gravity0.932 0.929 0.926 0.953 0.974 0.995 0.845

TABLE 14 Experimental Example 36 37 38 39 Mixing (A) Polyamide 25 45 6028 ratio (PA10T) (% by (B) Polyolefin 55 45 30 72 mass) (C)Compatibilizer 20 10 10 — (Anhydrous maleic acid-modified EBR “TafmerMH7020”) Mixing (B) was used after ◯ ◯ ◯ ◯ method mixing (A) and (C) (A)and (B) were mixed — — — — Prop- Charpy impact 5.0 2.1 3.8 1.1 ertiesstrength (kJ/m²) Flexural modulus (MPa) 910 1590 1620 1860 Specificgravity 0.944 0.987 1.017 0.860[2-5] Evaluation of Thermoplastic Resin Composition (II) (ExperimentalExamples 22 to 39)

Test pieces for evaluation obtained in Experimental Examples 22 to 39 ofthe above section [2-4] were subjected to measurement for Charpy impactstrength and flexural modulus according to the same method as the abovesection [2-2]. Results thereof were shown in Tables 12 to 14.

[2-6] Effects

According to the results in Table 12, Experimental Examples 28 in whichPA610 was used as the polyamide and the compatibilizer was not used hadflexural modulus of 1,730 MPa, but Charpy impact strength was as low as2.1 kJ/m².

On the other hand, Experimental Examples 22 to 27 in which PA610 wasused as the polyamide and the modified elastomer was used as thecompatibilizer had flexural moduli of 660 to 1,390 MPa, and Charpyimpact strengths of 5.4 to 40.0 kJ/m². It was found that ExperimentalExamples 22 to 27 were excellent in impact strength as well as rigidity.

According to the results in Table 13, Experimental Examples 35 in whichPA1010 was used as the polyamide and the compatibilizer was not used hadflexural modulus of 1,650 MPa, but Charpy impact strength was as low as1.1 kJ/m².

On the other hand, Experimental Examples 29 to 34 in which PA1010 wasused as the polyamide and the modified elastomer was used as thecompatibilizer had flexural moduli of 550 to 1,350 MPa, and Charpyimpact strengths of 2.1 to 40.0 kJ/m². It was found that ExperimentalExamples 29 to 34 were excellent in impact strength as well as rigidity.

According to the results in Table 14, Experimental Examples 39 in whichPA10T was used as the polyamide and the compatibilizer was not used hadflexural modulus of 1,860 MPa, but Charpy impact strength was as low as1.1 kJ/m².

On the other hand, Experimental Examples 36 to 38 in which PA10T wasused as the polyamide and the modified elastomer was used as thecompatibilizer had flexural moduli of 910 to 1,620 MPa, and Charpyimpact strengths of 2.1 to 5.0 kJ/m². It was found that ExperimentalExamples 36 to 38 were excellent in impact strength as well as rigidity.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed as limitingof the present invention. While the present invention has been describedwith reference to exemplary embodiments, it is understood that the wordswhich have been used herein are words of description and illustration,rather than words of limitation. Changes may be made, within the purviewof the appended claims, as presently stated and as amended, withoutdeparting from the scope and spirit of the present invention in itsaspects. Although the present invention has been described herein withreference to particular structures, materials and embodiments, thepresent invention is not intended to be limited to the particularsdisclosed herein; rather, the present invention extends to allfunctionally equivalent structures, methods and uses, such as are withinthe scope of the appended claims.

The invention claimed is:
 1. A plant-derived polyamide resin-containingthermoplastic resin composition that is obtained by molten blending apolyamide resin, a polyolefin resin that does not comprise a reactivegroup that reacts with the polyamide resin, and a compatibilizer,wherein the polyamide resin is at least one plant-derived polyamideresin selected from the group consisting of polyamide 11, polyamide 610,polyamide 614, polyamide 1010, and polyamide 10T, the content of thepolyamide resin is from 1% to 80% by mass based on 100% by mass of thetotal of the polyamide resin, the polyolefin resin, and thecompatibilizer, the content of the polyolefin resin is from 5% to 55% bymass based on 100% by mass of the total of the polyamide resin, thepolyolefin resin, and the compatibilizer, and the compatibilizer is anacid-modified olefin-based thermoplastic elastomer and the content ofthe compatibilizer is from 1% to 30% by mass based on 100% by mass ofthe total of the polyamide resin, the polyolefin resin, and thecompatibilizer, wherein the plant-derived polyamide resin-containingthermoplastic resin composition has a specific gravity from 0.89 to0.98.
 2. The plant-derived polyamide resin containing thermoplasticresin composition according to claim 1, wherein the compatibilizer is ananhydrous maleic acid-modified ethylene 1-butene copolymer or ananhydrous maleic acid-modified ethylene octene copolymer.
 3. Theplant-derived polyamide resin containing thermoplastic resin compositionaccording to claim 2, wherein the polyamide resin is at least oneselected from the group consisting of polyamide 11, polyamide 610,polyamide 1010, and polyamide 10T, and the polyolefin resin is apolypropylene.
 4. A molded article comprising the plant-derivedpolyamide resin-containing thermoplastic resin composition according toclaim 1, wherein the molded article is an exterior material, interiormaterial, or structural material for automobiles, rail vehicles, ships,airplanes, buildings, or furniture, or a housing or structural member ofa home appliance.
 5. The plant-derived polyamide resin containingthermoplastic resin composition according to claim 1, wherein saidcontent of said compatibilizer is in a range from 10% to 30% by mass. 6.The plant-derived polyamide resin containing thermoplastic resincomposition according to claim 5, wherein said polyamide resin ispolyamide 11, and wherein said compatibilizer is an anhydrous maleicacid-modified ethylene 1-butene copolymer or an anhydrous maleicacid-modified ethylene octene copolymer.
 7. The plant-derived polyamideresin containing thermoplastic resin composition according to claim 6,wherein the Charpy impact strength of said plant-derived polyamide resincontaining thermoplastic resin is from 18.2 to 86.3 k J/m².
 8. Theplant-derived polyamide resin containing thermoplastic resin compositionaccording to claim 1, wherein the Charpy impact strength of saidplant-derived polyamide resin containing thermoplastic resin is from 3.8to 86.3 kJ/m².
 9. The plant-derived polyamide resin containingthermoplastic resin composition according to claim 8, wherein saidcompatibilizer is an anhydrous maleic acid-modified ethylene 1-butenecopolymer or an anhydrous maleic acid-modified ethylene octenecopolymer.
 10. The plant-derived polyamide resin containingthermoplastic resin composition according to claim 1, wherein theflexural modulus of said plant-derived polyamide resin containingthermoplastic resin is from 710 to 1380 MPa.
 11. The plant-derivedpolyamide resin containing thermoplastic resin composition according toclaim 10, wherein said compatibilizer is an anhydrous maleicacid-modified ethylene 1-butene copolymer or an anhydrous maleicacid-modified ethylene octene copolymer.
 12. The plant-derived polyamideresin containing thermoplastic resin composition according to claim 1,wherein said polyamide resin is at least one resin selected from thegroup consisting of polyamide 11, polyamide 610, and polyamide 1010, andwherein the Charpy impact strength of said plant-derived polyamide resincontaining thermoplastic resin is from 4.8 to 86.3 kJ/m².
 13. Theplant-derived polyamide resin containing thermoplastic resin compositionaccording to claim 12, wherein said compatibilizer is an anhydrousmaleic acid-modified ethylene 1-butene copolymer or an anhydrous maleicacid-modified ethylene octene copolymer.
 14. The plant-derived polyamideresin containing thermoplastic resin composition according to claim 1,wherein said polyamide resin is at least one resin selected from thegroup consisting of polyamide 11, polyamide 610, and polyamide 1010, andwherein the flexural modulus of said plant-derived polyamide resincontaining thermoplastic resin is from 710 to 1380 MPa.
 15. Theplant-derived polyamide resin containing thermoplastic resin compositionaccording to claim 14, wherein said compatibilizer is an anhydrousmaleic acid-modified ethylene 1-butene copolymer or an anhydrous maleicacid-modified ethylene octene copolymer.
 16. The plant-derived polyamideresin containing thermoplastic resin composition according to claim 1,wherein said polyamide resin is polyamide 11, and wherein the Charpyimpact strength of said plant-derived polyamide resin containingthermoplastic resin is from 6.4 to 86.3 kJ/m².
 17. The plant-derivedpolyamide resin containing thermoplastic resin composition according toclaim 16, wherein said compatibilizer is an anhydrous maleicacid-modified ethylene 1-butene copolymer or an anhydrous maleicacid-modified ethylene octene copolymer.
 18. The plant-derived polyamideresin containing thermoplastic resin composition according to claim 1,wherein said polyamide resin is polyamide 11, and wherein the flexuralmodulus of said plant-derived polyamide resin containing thermoplasticresin is from 710 to 1211 MPa.
 19. The plant-derived polyamide resincontaining thermoplastic resin composition according to claim 18,wherein said compatibilizer is an anhydrous maleic acid-modifiedethylene 1-butene copolymer or an anhydrous maleic acid-modifiedethylene octene copolymer.
 20. A plant-derived polyamideresin-containing thermoplastic resin composition that is obtained bymolten blending a polyamide resin, a polyolefin resin that does notcomprise a reactive group that reacts with the polyamide resin, and acompatibilizer, wherein the polyamide resin is at least oneplant-derived polyamide resin selected from the group consisting ofpolyamide 11, polyamide 610, polyamide 614, polyamide 1010, andpolyamide 10T, the content of the polyamide resin is from 55% to 80% bymass based on 100% by mass of the total of the polyamide resin, thepolyolefin resin, and the compatibilizer, the content of the polyolefinresin is from 10% to 40% by mass based on 100% by mass of the total ofthe polyamide resin, the polyolefin resin, and the compatibilizer, andthe compatibilizer is an acid-modified olefin-based thermoplasticelastomer and the content of the compatibilizer is from 5% to 30% bymass based on 100% by mass of the total of the polyamide resin, thepolyolefin resin, and the compatibilizer, wherein the plant-derivedpolyamide resin-containing thermoplastic resin composition has aspecific gravity from 0.89 to 0.98.